my mk5 cortina estate

[ian f]

had to work fast today as heavy rain was forecast so painted inside, trimmed the repair panel, clamped up and tacked it in plug welded the bottomshort seam welds being built up and complete didn't grind it today will do that in the week as i ran out of daylight just gave it a holding coat of primer

 

[ian f]

got the inner valance made and welded in yesterday while we had some "decent" weather. my mate is going to help me build a carport after christmas but until then i'm at the mercy of the weather, my days of welding in the rain are over i've decided! before anybody says it i'm going to try and reprofile the swages on the left to make them the same length as the others

 

[ian f]

bringing this thread back from the dead. finally got my "carport" more or less finished so i can now concentrate on getting the cortina done

 

[God mode restorations]

Hi...
nice to see an old school ford..and superbly made panels..great stuff...

 

[zardoz]

Nice to see The Mk5 still on the way. Well done on the carport too. wish I had one, thats for sure.

 

[ian f]

hi last weekend i started cleaning off the rubberised under seal from the boot floor and found some more rot of course so cut an hole from above to get better access view from above deciding how much to cut out and repair panel made it doesn't need to be perfect as it's hidden by the petrol tank

 

[ian f]

but before going any further on that piece i need to make a new petrol tank mountwhich is a little crustyso cut a new piece of 1.5mm steel and folded it overclamp in the vice and open the ends up a littlethen smack the living crap out of it until it takes the correct shapeready for trimmingthen weld on the extra pieces that attach it to the chassis

 

[anjum]

I'm speechless.......

 

[ian f]

had a good go at the car last week. i thought i'd posted it here but obviously didn't first piece the vertical part of the boot floor which has to go on before the chassis repair

then welded in sorry it looks a bit rough i had the wire speed a little high

then the "boot floor bottom" was welded in

i should mention the chassis repair which is the part where the petrol tank mount welds to, it was a bit thin on two sides so i cut them out and welded new pieces in sounds easy but was a right pain but was made easier having bought a evolution powerfile to get in to clean up the area

side piece on

then the bottom next job should be welding the tank mount on

 

[steveo3002]

good stuff , i like the panels you are making

could you post more pics of how you make the panels please

 

[ian f]

i knew i'd forgot somethingthe same time i did all the above i also closed off the cut outs that i did to gain access to the lower boot floor i had to do this as it was covered in waxoil but i suspect the panels were rusting away when i injected it many years ago. so first piece tacked in

then number 2

and the last

then go round doing a couple of spots until filled in

then clened off with a flap disc and the powerfile, not perfect but good enough

 

[CRB]

Glad you resurrected the thread.

Flippin' brilliant.

 

[marlinspike]

Nice work. I don't know how you manage to get those short runs without blowing through. Is the metal pretty thick in Cortina boots?

 

[ian f]

good stuff , i like the panels you are making

could you post more pics of how you make the panels please

hi, i'll try and take more pics

 

[ian f]

Nice work. I don't know how you manage to get those short runs without blowing through. Is the metal pretty thick in Cortina boots?

not thick metal at all, 20 gauge or 1mm i reckon plus i cleaned up the edges with the powerfile so probably a bit thinner it's just a case of expecting it to blow through and stopping before it doesmust admit i got it wrong a few times though forgot to add the final pic yesterday sorry

 

[ian f]

more rust i swear one day i'll get this thing finished. so, the spare wheel well seemed pretty solid

but when i was doing the petrol tank mount i noticed it was very thin in many places, if i dont sort it now i'm going to have to do it in a year or so

so using the spare wheel i cut out a blank

which i then started to hollow into a sandbag

then added the pressings for the drain plug holes

paint and spare wheel bracket removed to enable copying of swages in floor

then added to new panel by chasing into sandbag with a rounded flat chisel

then edge hollowed into bag to give some curvature

view from underneath, doesn't need to be perfect

then another trial fit

 

[Rocketman]

Great work. Always look forward to the next instalment. It usually involves rust and panel manufacturer

 

[ian f]

time to make the drain hole plugs

clamp socket and blank in the vice

and smack over socket with plastic hammer

then flatten out where required with flat bar to make step

then open out with small hammer

leaving this which needs dressing flat

like so

then trim edge

 

[normspanners]

This is not a ford cortina
it should be renamed an IAN F CORTINA.
coz there is more of your panels than fords.
Your not from India are you?

 

[ian f]

then after all that i realized the "step" in the middle of the panel isn't as pronounced as i thought more of a gentle pressing hope that makes sense

so had to dress it down with a plastic hammer and block of wood. then holes cut out for the drain plugs

and finally trial fit with plugs

laid in position