Guest dee1orean Posted April 16, 2009 Share Posted April 16, 2009 Been a while since I've updated. Not had much opportunity to work on her for a while as the students have been busy with their assessment tasks so as it's currently half term I thought I'd get in the workshop and crack on with some welding. It's great having the workshop to myself lol! So for those who like pics of holes being filled (Ohh err missus!!) Passenger side sill For some reason I didn't take a pic of this after plating it but it is done. will take a pic when I'm next there. Also smoothed the rear bootlid numberplate recess as I've cut one out of the rear bumper. This has no been ground down and filled again I'll take a pic when I'm next there. Essential Welding still to do... Battery tray Windscreen frame bottom corners Front slam panel Roof mount panel where the roof bolts on has rusted through and ripped Modification welding to do (if I decide to carry out these mods!) Fuel filler cap hole after relocating fuel neck to behind rear light. Side repeater holes in wing Door handles and lock holes Rear bootlid arms rather than the current top hinge setup. So still lots to do! Quote Link to comment Share on other sites More sharing options...
Escort Cabriolet Club Posted April 17, 2009 Share Posted April 17, 2009 Thats what I call Tin-Worm !!! The patching up is slow but its getting there mate, keep us posted !!! :clap: Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted May 2, 2009 Share Posted May 2, 2009 Thats what I call Tin-Worm !!! Ha!! You ain't seen nothing yet!! The remains of my battery tray area!! :wow: So out came the dash, heater pipework and the sound deadening behind the hole. I'll crack on with removing the battery tray remains and the welding next week. Had one of the students welding the holes near the rear lights and another filling over my welding of the door sills. So she's coming on. Don't think she'll be ready for the summer tho ah well! Quote Link to comment Share on other sites More sharing options...
Guest steelcabby Posted May 2, 2009 Share Posted May 2, 2009 hey chap, you got alot of rot on that car, good to see you cracking on with it... those ford battery trays are rubbish. here is my idea...........remove the tray, weld a new plate where the old tray was. then weld a new angled tray or plate in that area for your new battery. the reason they go there is due to the way water sits on the tray, along with leaking batteries of course. an angled tray would help to shift any water etc. make a work of art out of it and it would be nice and different. whoop whoop Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted May 2, 2009 Share Posted May 2, 2009 hey chap, you got alot of rot on that car, good to see you cracking on with it... those ford battery trays are rubbish. here is my idea...........remove the tray, weld a new plate where the old tray was. then weld a new angled tray or plate in that area for your new battery. the reason they go there is due to the way water sits on the tray, along with leaking batteries of course. an angled tray would help to shift any water etc. make a work of art out of it and it would be nice and different. whoop whoop Sounds like a plan! fabricating a battery tray shouldn't be too much of a problem and I like the idea of angling it slightly to let water run off. I know there's a lot of rot in this car and people keep asking me is it worth it... Maybe in monetery value it's not but in terms of experience and sentimental value I feel it is. I figure if I can tackle this then I can pretty much tackle anything as they don't come much worse LOL I want to be able to offer a restoration\modification service in the future, not just for old escorts but for anything really So I want to be able to use this as an example of the work I can turn out. I also plan on starting a smart repair business in about a year or so, similar to chips away but working for myself. already have my business name, "Lord of the Dings", "looking after your precious" What dya think!!!lol So yeah, back to the car. the only other major welding area to do after the battery tray is the front slam panel and then that's all the major essential welding done. Then it's on to the modification welding, Door Handles and Locks, fuel filler hole, already done the ariel hole as you can tell I'm going for the Smoooth look lol! I'm planning on videoing the paint process too, which should make for a fun little vid lol. Quote Link to comment Share on other sites More sharing options...
Guest steelcabby Posted May 2, 2009 Share Posted May 2, 2009 (edited) sounds good chap. glad your keen.....i'm starting my own business too next year. going to break rs's and cabbies, but restore the shells to sell on. restore as in shot blast, panels and welds. then sell fully undersealed and primered ready for colour choice. i'm an ex legendary welder. so no job too small for me within reason...pmsl. my next cabby will be a blinder, and tilted tray is one of my ideas for it, either that or a rear quarter panel sealed battery, so i can get rid of that nasty battery tray. pain in the bum bum they really are.....very poor design Edited May 2, 2009 by steelcabby Quote Link to comment Share on other sites More sharing options...
Escort Cabriolet Club Posted May 3, 2009 Share Posted May 3, 2009 That battery tray is pure Carnage !!! :wow: Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted May 15, 2009 Share Posted May 15, 2009 Time for an update. Finally removed the Battery tray to expose the horror beneath, it was being extremely stubborn. Pic of new bulkhead plate cut to size and offered up: Excellent fit for a patent part. this has since been bare metaled and zinc primed ready to weld in. the area around the hole has also been cleaned up, treated with Kurust and zinc primed ready for welding next week. I'm still deciding whether to go for the custom Battery tray or thge original Battery tray which i also have. If I replace it with the original it will most likely survive the life of the car... More pics of some students working on my car: Plates made up for the ultra rotton slam panel by Matt: And here he is welding them in!: Here Ramsey is baremetaling all the rust scabs inside the rear tailgate, treating them with Kurust and zinc priming them to ensure they don't rust again before Primer. Bare metaling: After treating: This is Danny doing some detail sanding around the lower edge of the windscreen: And this is Louis, Looking none to pleased about having his picture taken lol, Putting the finishing touches to the smoothed bootlid: They all put a lot of effort in today, I think they'll go on to make excellent Panel Beaters\Painters. More pics next week hopefully. Quote Link to comment Share on other sites More sharing options...
Escort Cabriolet Club Posted May 16, 2009 Share Posted May 16, 2009 Cool update mate !!! Loving this topic very much, its coming along well, less and less rot every time I read an update !!! :icon_salut_gb: Quote Link to comment Share on other sites More sharing options...
Guest Spudster Posted May 16, 2009 Share Posted May 16, 2009 Where did you get this from, had to fabricate one myself, seen them in packages with battery tray. Good Progress mate, coming along nicely, can they work on my car too? ha! Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted May 17, 2009 Share Posted May 17, 2009 The Panel is a Hadrian Part from our local stockist: http://www.perfectpanels.co.uk/index_catalogues.htm They have pretty much everything for every car!! you can find your local stockist from the above website. The MK4 Battery tray area comes in either a one piece combined bulkhead & Battery tray or two separate pieces, I got the two seperate pieces as I'm still deciding whether to fabricate my own battery tray or not. Both pieces only cost £24. Charlzy, glad your enjoying the thread, I'm enjoying writing it!! also really enjoying the project too, though it's taking longer than I originally thought once it's all done she should have a long life ahead of her. Quote Link to comment Share on other sites More sharing options...
Guest hagondaz Posted May 17, 2009 Share Posted May 17, 2009 well good thread here, good inspiration to everyone with a project i recon. keep it up, Quote Link to comment Share on other sites More sharing options...
Escort Cabriolet Club Posted May 18, 2009 Share Posted May 18, 2009 Charlzy, glad your enjoying the thread, I'm enjoying writing it!! also really enjoying the project too, though it's taking longer than I originally thought once it's all done she should have a long life ahead of her. LOL, got all the time in the world mate, i'm doing the same with mine, its done when its done lol !!! Quote Link to comment Share on other sites More sharing options...
chaz Posted May 19, 2009 Share Posted May 19, 2009 This is really good to see, the students look like they are up to it. Keep updating mate. Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted May 19, 2009 Share Posted May 19, 2009 well good thread here, good inspiration to everyone with a project i recon. keep it up, Awww Shucks now I'm all embarressed LOL!!! Thanks mate! the students look likethey are up to it. I'm very choosy as to which students I let work on it, believe me we have some who really should not be let loose with sandpaper let alone power tools LOL!! But they all seem to be really keen, and enthusiasm goes along way. Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted May 26, 2009 Share Posted May 26, 2009 It's half term again, these bleeding kids have too much time off. So once again I have the workshop to myself so was able to crack on a bit.: Topless pic.... What? why what were you thinking??? After taking off the roof look what I found: These are the bolts that anchor the roof to the car. The idea is too weld in a patch plate, drill holes , thread bolts through and weld in place.... Should work in theory. To the front: Swiss cheese: Nice new metal... still needs finishing off though.... And the battery tray bulkhead support panel. Sealer hides all kinds of interesting welding techniques!!! That's it till next time. Quote Link to comment Share on other sites More sharing options...
Guest michaelw Posted May 26, 2009 Share Posted May 26, 2009 Good work there! Looking forward seeing it finished Quote Link to comment Share on other sites More sharing options...
Escort Cabriolet Club Posted May 26, 2009 Share Posted May 26, 2009 Never seen tin worm do that much carnage !!! Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted June 13, 2009 Share Posted June 13, 2009 Hello evry1!!! Okay!! time for a small update A small patch welded in on the Drivers side front Chassis leg, this has now been ground down and filled over: Battery tray finished, Soz Steely I did go for the original design part after all but at least your tilted tray design will be unique to you eh? Ohh!!! my sexy looking new boot Yummy!!!! Sanded it all down removed the sound deadening, welded up four holes in the spare wheel well Slapped Kurust all over it lol! then stone chipped the entire boot floor area. I'm really pleased I think it looks brand new!!! I'l probably do the same for the passenger cabin floor panels too: And the last pic for today.... Just when you think you're making some progress, one of your work collegues decides to reverse your car into the exposed chassis leg of a work in progress Ford KA Pickup truck resulting in: I was not best pleased!! It's really not that bad, and considering what I've already repaired on this car it should be a walk in the park lol! That's it for now as usual all comments encouraged and welcomed. Ta Muchly! Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted June 13, 2009 Share Posted June 13, 2009 I was just thinking, As we now have a Restoration thread thingy if one of you admin Mod type people fancy moving this topic thread there that'd be just grand!!! Ta! Quote Link to comment Share on other sites More sharing options...
Guest clacky Posted June 13, 2009 Share Posted June 13, 2009 just read the whole thread that you have posted and it is very inspirational !! love the work that you are doing and cant wait to see the finished car working on a 1990 mk4 xr3i cabby myself and your work has given me some ideas to work into my project also keep up all the good work and congrats to you and all your team cheers chris Quote Link to comment Share on other sites More sharing options...
Escort Cabriolet Club Posted June 13, 2009 Share Posted June 13, 2009 Some more tough jobs done mate !!! Quote Link to comment Share on other sites More sharing options...
allblue Posted June 14, 2009 Share Posted June 14, 2009 I really like this thread That car is in a pretty bad way rust wise, but the work you are putting into that cab is top dollar. Its nice to see things starting to take shape. Quote Link to comment Share on other sites More sharing options...
Guest dee1orean Posted June 17, 2009 Share Posted June 17, 2009 Thanks for all the positive replies guys, I really do appreciate the encouragement! Just a couple of pics from tuesdays progress: Did some work on the bootlid, the lower portion has already been filled and smoothed off. As I was keying up the top portion I noticed signs of a dent on the right hand side so I continued to sand this area to find a really bad repair where filler had been applied over paint. This is very bad practice as you are not supposed to do this. You can apply Stopper over paint or Primer but filler should ideally only be applied over bare metal. So after digging all the paint and filler out taking it down to bare metal I used the Rose spot gun and slide hammer to pull the dent out as ther rear of the dent was inaccessable due to the panel strenghthening behind it. The following pics are not of me but are just to demonstrate the process: 1st a pin is welded to the dented area using the Rose Spot gun: Then the slide hammer is attached to the pin and using the sliding handle the dent is pulled out. The pins can then be pulled or ground off, be careful if pulling them off as they can tear the metal and leave a hole... Not ideal! I found that the metal in this area had stretched a bit so I used a gridded faced shrinking hammer to tighten the metal up: Then applied filler to the area, I found that I was having difficulty feathering of the repair area into the original paint so I decided to bare metal the entire section and in doing so found three more dents where it looks like it's been reversed into something. So again these where filled as they weren't as bad as the first one. still have to sand this area down will post pics when it's done. Just a couple of quick comparison pics: From this: To this: Looks much better doesn't she?!!!! Quote Link to comment Share on other sites More sharing options...
Guest hagondaz Posted June 17, 2009 Share Posted June 17, 2009 front ends looking sounds brand new, keep up the good work. Quote Link to comment Share on other sites More sharing options...
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