Sierra XR4i full restoration.

[Onoff]

Yes, I do recall Cardinal was what my brother called it.

Sadly not mine but the same year / colour (Cardinal Red over Stratos Silver). Looks a lot darker than yours but this is a metallic:

 

[AVI_8]

Sadly not mine but the same year / colour (Cardinal Red over Stratos Silver). Looks a lot darker than yours but this is a metallic:

View attachment 327289

I think the Sierra is Rosso red?
Capri brings back fond memories, had a 3.0 Sport back in the 80s, they’re like hens teeth now.

 

[Onoff]

I think the Sierra is Rosso red?
Capri brings back fond memories, had a 3.0 Sport back in the 80s, they’re like hens teeth now.

(I have a black 2.0S)

@Domdom this might help by reference to the VIN tag:

Paint colors for Ford (europe) Sierra cars | PaintColourChart.com

www.paintcolourchart.com

Think your date of manufacture is 1983.

 

[daedalusminos]

I must finish off my XR-4i... I've had it about 35 years...

 

[Domdom]

Definitely Cardinal red from 1982. Looks like Ford might have re-sued the name after 1988 which is a metallic colour. I did get a touch up spray made up before we knew the extent of the tin worm and that say Cardinal red.

Capri brings back fond memories, had a 3.0 Sport back in the 80s, they’re like hens teeth now.

No love for the Capri here. My dear old Mum had several, a 2.0 GL and a few 2.8i ones. They were the bane of my life, constantly needing attention, awful to drive, handled like a hovercraft and you could have a 48 person banquet off that bonnet. Looked great, but then so do a lot of women in the modelling game. Just not easy to live with.

 

[Domdom]

Evening all. Did some more today, mostly around refitting panels. To get the wings in the right place needed the bonnet on along with the bonnet catch, the landing buffer things and the scuttle trim underneath the screen. lining it up is no easy job, especially with it being heavy and high up on this jig. But having no reference points doesn’t help either. It’s like a bloody Rubiks Cube to be honest.

Anyway, I started with the scuttle trim, acquiring a blood blister pinch along the way. Ouch and other things were uttered. A quick stab with a stanley blade, squeeze out the blood and a plaster and back to it.

Fitting the bonnet I tried using the screw shadows from where it was previously, kind of logical I thought right up to the point the scuttle trim gap was really uneven. This was adjusted to get an even gap and I then measured from a front bonnet corner to the bottom of the A pillar where the screen touches it. Both sides compared and 12mm out. So I refitted the landing pads for the bonnet front and also the catch. I put the catch back according to screw marks and sure enough the bonnet wouldn’t close. Quite literally an hour making 4 adjustments to the bonnet hinges, maintaining both the scuttle trim gap and screen to front measurements and the bonnet closed beautifully.

Temporarily fitted both front wings with tack welds. I was getting the panel gaps quite reasonable and feeling smug……until I tried to fit the nosecone. Nope, gap too small. Fiddlesticks!

So I think I’m trying to make the wing to bonnet gaps too small. Tomorrow is another day.

 

[Onoff]

As a rule of thumb when panelling up the front end, aimed for gaps on the Capri are nominally "the thickness of a Pound coin".

 

[daedalusminos]

Is the bonnet not meant to seat onto the nose-cone rubber?

 

[RWD3M]

Hi Dom,

Those wing to bonnet gaps look a bit on the big side to me. Been a loooong time since I've had the joy of doing a Sierra front end, but Im fairly sure I remember them being a good bit tighter than that.

Great to see the progress by the way!

 

[Cris B]

Project looks to be progressing well, I am somewhat envious of the fact that you have access to replacement repair panels. I know Russ Dack through car friend connections, have you seen his Cossie?

There is a thread on PassionFord but the photos were all lost during the PhotoBucket débâcle

 

[Domdom]

Project looks to be progressing well, I am somewhat envious of the fact that you have access to replacement repair panels. I know Russ Dack through car friend connections, have you seen his Cossie?

View attachment 328263

There is a thread on PassionFord but the photos were all lost during the PhotoBucket débâcle

Yeah, replacement panels, sort of. Only 4 door stuff available generally, nothing XR4i specific like wings, outer sills etc.

Not seen the Cosworth you mention but I do like the look of the 3 door hatch, always did. I did look at a Rouse Sapphire some years back but just don't like the shape. That was a monster thing though, just not for me. I like older cars and have a real soft spot for the Rover P6 which I will probably do next. The 3500 is so easy to make modern for reliability (less so the 4 cylinder engines) by adding EFI, full electronic distributor-less ignition, 5 speed box, change the diff to an XJS unit. You end up with a very usable daily.

The one Cosworth I did find interesting was up for sale a while back, might still be. Quite high mileage, ex Ford test car etc but the only one which came in red from the factory. https://www.bonhams.com/auctions/25448/lot/250/ although no idea where it is now.

But seriously, 125k for a RS500? Erm, no ta. Not much difference to the standard car at the time. Only the track cars had the 2nd row of injectors enabled, slightly larger turbo etc. And still a Ford. Not a Ferrari. Maybe if it was an RS200.....now those are super rare now. I do recall the Kent Police having one at the time.

 

[Domdom]

Right , more fettling. Started by hanging the driver’s door which took longer than expected. Adding another piece to the puzzle does seem to confirm that the panel gaps are probably not too far off. The pound coin does seem to be a good measure from the rear of the door to rear quarter, leading edge of the door to the wing, those are OK. Big by modern standards though.

Getting the wing to bonnet gaps is way harder though. That said, one wing is Ford and the other is pattern and there are noticeable differences.

I know the bonnet is right as it measures well and the catch is in the original position. But all this messing about is more than tedious, especially as I can’t use grips or clamps to hold it cos the bonnet won’t close. Has to be tack welded every time And then ground back to move it.

A few photos of my efforts. I’m very nonplussed by it tbh. Several hours work and I still don’t like it.

 

[Domdom]

Well, I thought I would give you all a laugh this fine Sunday morning.
Behold, my brother’s descriptive parts labeling system.
These are, of course. Bonnet landing pads

 

[RWD3M]

Well, I thought I would give you all a laugh this fine Sunday morning.
Behold, my brother’s descriptive parts labeling system.
These are, of course. Bonnet landing pads

View attachment 329315

Brilliant!

How are you getting on with those bonnet gaps?

 

[minimutly]

Brilliant!

How are you getting on with those bonnet gaps?

Start at the pillars and work forwards?

 

[Domdom]

Brilliant!

How are you getting on with those bonnet gaps?

Coming along nicely. Had a chat with the chairman of the XR Owner’s Club and he sent me the measurements from his own car. The issue was I was trying to get 2022 gaps on a 1983 car. The gaps should be 7/32” where I was aiming for about 5/32 to 3/16” which is too small.
My Brother was here today helping out and we got loads done including the dry fit of the wings. Both off again while I repair the last few bits on them but all good to go back on now.
Also tested the body kit bits which all line up, marvelous!
So now just have to finish the wings, make up 2 small bits to join the rear seat box to the inner sills, weld on the passenger front seat strengthening bit and weld on the battery tray. Then it’s off for paint.

 

[Onoff]

7/32"... really, that's 5.5mm.

As I said, the aimed for gaps with the Capri is the old Pound coin that was nom 3.15mm.

 

[Domdom]

7/32"... really, that's 5.5mm.

As I said, the aimed for gaps with the Capri is the old Pound coin that was nom 3.15mm.

This is from a show winning car.

 

[Onoff]

This is from a show winning car.

Looks more like 3/16" to me. Pity they didn't use a Vernier.

 

[Domdom]

Looks more like 3/16" to me. Pity they didn't use a Vernier.

That's painted. though. Also, 3/16" is 4.8mm against the 3.15mm of an old pound coin.