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Mk4 Cabriolet - Rs Turbo Brand New Shell Restoration

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Hi all

Just a brief history and a few pics of my Mk4 restoration/Project

Ive owned the car since 1994 and enjoyed many years driving it about, but in 2001 it popped a driveshaft whilst my wife was driving it home from work late one night leaving her stranded and decided it was time for her to have a new car, so not long after we ended up at the local Ford dealers and bought a Brand New Fiesta Zetec S.

I run the cab until the tax run out and then parked her up, it stayed that way for a good while whilst I build my garage. When it was finished I began the restoration stripping the car back to a bare shell, I found a few rust spots in all the usual places, battery tray rear arches wings/front panel as well as the outer Sills & on the inner wings close to the hinge mountings. I was surprised to find how good the floor was though.

I then set out trying to source new genuine panels required to repair the old shell but after a few years of looking and finding every panel apart from the drivers rear quarter panel the opportunity came along to purchase a brand new Shell, the old shell was then abandoned (I regret this now tho).

Its now awaiting a rollover jig to be made and a few more exterior parts and then the resto can finally truly begin.

 

Garage.jpg

RS Turbo 33.jpg

RS Turbo 38.jpg

Brand New Shell - Still in factory primmer

rs1.jpg

New Genuine Spare Body Panels

New Genuine RS Turbo Bonnet (To Be Used On The Cab)

rs200.jpg

New Genuine  Front Wings

rs201.jpgrs202.jpg

New Genuine Front Panel

rs203.jpg

New Genuine Cross Member

rs204.jpg

New Genuine Scuttle Panel

rs200a.jpg

New Genuine Doors (Passenger Door x2 - 1 Fitted to New Shell & 1 Painted by Previous Owner)

rs205.jpgrs206.jpg

New Genuine Rear Quarter Panels

rs207.jpg

rs207a.jpg

New Genuine Boot Floor

Bootfloor.jpg

New Genuine Mk4 Boot Lid

rs209.jpg

New Genuine Rear Lower Valance

rs210.jpg

New Genuine Light Cluster Panels

rs208.jpg

rs208a.jpg

 

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Lights

New Genuine Corello Headlamps

rs20.jpg

New Genuine Headlamp Covers

rs20a.jpg

New Genuine Indicators

rs23.jpg

New Genuine Corello 640 Spot Lamps 

rs25.jpg

New Genuine 90 Spec Spot Lamp Brackets

rs25a.jpg

New Genuine Spot Lamp Bracket Backing Plates

rs25b.jpg

New Genuine side Repeaters

rs28.jpg

New Genuine Rear Light Clusters

rs26.jpg

New Genuine Rear Light Cluster Gaskets

rs26b.jpg

New Genuine Rear Light Cluster Bulb Holders

rs27.jpg

New Genuine Number Plate Lamp

rs30.jpg

New Genuine Head Lamp Fixings

rs21.jpgrs22.jpgrs24.jpg

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Wheels

New Genuine RS Turbo Wheels & Centre Caps

rs2.jpg

Used Steel Wheels Awaiting Refurb

3i Wheels.jpg

New Genuine Steel Wheel Trims

3i Trims.jpg

New Genuine  wheel Nuts

rs4b.jpg

New Genuine  Locking Wheel Nuts

rs5.jpg

 

 

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Bumpers & Body Kit

New Genuine Front 90 spec Bumper

rs7a.jpg

New Genuine Rear Bumper

rs7b.jpg

New Genuine Black Bumper Trim 

rs18.jpg

New Genuine Full Complete RS Turbo Body Kit (2x Passenger Side)

rs8.jpg

DSC08560.jpg

rs10ba.jpg

rs10bb.jpg

rs10.jpg

rs10cc.jpg

rs9.jpg

rs9b.jpg

rs9a.jpg

New Genuine Body Kit Retainers

rs8a.jpg

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Glass

New Genuine Green Tint Heated Windscreen

rs44d.jpg

New Genuine Green Tint Drivers Fixed Glass

rs47.jpg

New Genuine Green Tint Passenger Drop Glass

rs46.jpg

New Genuine Green Tint Drivers Rear Quarter Drop Glass

rs48.jpg

New Genuine Green Tint Passenger Rear Quarter Drop Glass

rs48b.jpg

New Genuine Windscreen Rubber

rs45.jpg

New Genuine Radio Decode Stickers

rs48e.jpg

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Roof

New Genuine Outer Roof Skin

rs93a.jpg

New Genuine Roof Padding

rs93h.jpg

New Genuine Front Roof Seal

rs95.jpg

New Genuine Roof Cables

rs96.jpg

New Genuine Rollover Bar Padding

rs97.jpg

New Genuine Handle Fixing Covers

rs98.jpg

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Electrics

New Genuine 90 Spec XR3i EFi Cab Body Harnes

rs28a.jpg

New Genuine Fusebox Cover

rs62.jpg

New Genuine Battery Cables

rs71a.jpg

New Genuine Electric Window Switches

rs39a.jpg

rs41.jpg

New Genuine Electric Roof Switch

rs94.jpg

New Genuine Indicator Side Repeater Looms

rs29.jpg

New Genuine Indicator Stalk

Stalk.jpg

 

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Dash

New Genuine Dashboard

RS-Turbo-Parts.jpg

 

New Genuine Glove Box Surround

rs33.jpg

New Genuine Speedo

rs32a.jpg

New Genuine Dash Switches

rs39c.jpg

New Genuine Centre Vent & Heater Control Panel

rs34a.jpg

New Genuine Heater Knob

rs34d.jpg

New Genuine Radio Surround & Ash Tray

rs34.jpg

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Steering Column

New Genuine 3 Spoke steering Wheel & Horn Push

rs31.jpg

New Genuine Steering Wheel Boss (I Did Fit This But Removed It Again For Storage)

rs32.jpg

New Genuine Column Surround

rs34b.jpg

rs34c.jpg

Refurbed Steering Column

rs34f.jpg

New Genuine Steering Column Bulk Head Grommet

rs76.jpg

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Centre Console

New Genuine Tape Holder

rs34e.jpg

New Genuine Gear Knob

rs35a.jpg

New Genuine Gearstick Gaiter

rs35.jpg

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Exterior Trim

New Genuine Ford Badges

rs6.jpg

New Genuine wing Welts

rs15.jpg

New Genuine 88 & 90 Spec Boot Decals

rs7.jpg

XR3i 90 Spec Front Wing & Boot Decals

DSC00320.JPG

New Genuine Door Handles

rs11.jpg

New Genuine Tibby Lockset

rs12a.jpg

New Genuine Tibby Fuel Cap

rs14a.jpg

New Genuine Chubb Lockset

rs13.jpg

New Genuine Chubb Fuel Cap

rs14.jpg

New Genuine Door Fame Top Finishing Caps

rs12.jpg

New Genuine Black Side Mouldings (Missing Passenger Side Quarter to Complete Full Set)

rs16.jpg

rs16a.jpg

rs16e.jpg

New Genuine Boot Hinge Covers

rs19.jpg

New Genuine Electric Antenna Mask

rs25c.jpg

New Genuine Electric Antenna Fixing Kit

rs25d.jpg

 

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Rubbers & Seals

New Genuine Drivers A Post Screen Pillar Seal

rs44a.jpg

New Genuine Set of Cabriolet Outer Door Weatherstrips

rs49.jpg

New Genuine Passenger Door Weatherseal Finishing End Seal

rs51.jpg

New Genuine Set Of B Post Seals

rs53a.jpg

New Genuine Set Of Front Part Door Aperture Seals

rs52.jpg

New Genuine set Of Rear Part Door Aperture Seals

rs53.jpg

New Genuine Set of Inner Quarter Panel Windows Seals

DSC08535.jpg

New Genuine Roof C Post Seals

cabstops.jpg

New Genuine Boot Aperture Seal

rs54.jpg

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Suspension & Steering

New Genuine Front shocks

rs55.jpg

New Genuine Front Strut Caps

rs57.jpg

New Genuine Front Strut Top Rubbers & Bearings

rs56.jpg

New Genuine Front Wheel Bearings

rs59.jpg

New Genuine Track Control Arms & Anti Roll Bar Rubbers

rs55b.jpg

New Genuine Anti Roll Bar Washers

rs59k.jpg

New Genuine Anti Roll Bar Front Mounting

rs59f.jpg

New Genuine anti Roll Bar Clamps & Fixings

rs59c.jpg

New Gen Anti Roll Bar Front Rubbers

rs59e.jpg

New Genuine Rear Shocks

rs55a.jpg

New Genuine Rear Top Shock Absorber Rubbers

rs56a.jpg

New Genuine Rear Spring Isolators

rs59dd.jpg

New Genuine Rear Hub Nut Covers

rs59h.jpg

New Genuine Steering Rack Mounting Rubbers

rs54k.jpg

New Genuine Track Rod Ends

rs55c.jpg

Rear Suspension Arms Fixing Bolts & Nuts

rs59g.jpg

rs59j.jpg

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Interior

New Genuine Interior Mirror

rs37.jpg

New Genuine Carpet

rs30a.jpg

New Genuine Pedal Rubbers

rs38.jpg

New Genuine A Pillar Cover

rs30c.jpg

New Genuine Rear Window Winder Handles & Caps

rs40.jpg

rs40a.jpg

New Genuine Passenger Front Seat Belt

rs42b.jpg

New Genuine Front Seat Belt Latch

rs42c.jpg

New Genuine Cabriolet Rear Seat Belts

rs43.jpg

rs43b.jpg

New Genuine Inner Door Release Handles

rs39b.jpg

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Door Mirrors

New Genuine Drivers Electric Mirror

rs48c.jpg

New Set Of Heated Mirror Glass

rs48d.jpgrs48a.jpg

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Seats

New Genuine Recaro Seat Base Foams

rs38d.jpg

New Genuine Recaro Left Hand Seat Bolster Foam

rs38e.jpg

New Genuine Set of Recaro Base Supports 90 Spec Material

rs30b.jpg

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Engine Bay

New Genuine Header Tank & Cap 

New Genuine 88 Spec Master Cylinder Brake Fluid Reservoir

New Genuine 88 & 90 Spec Screen Washer Bottles

rs11a.JPG

New Genuine 90 Spec Brake Master Cylinder

rs63a.jpg

New Genuine Screen Washer Pipe & Clips

rs80.jpg

rs81.jpg

New Genuine Bonnet Latch

rs60.jpg

New Genuine Bonnet Catch

rs60a.jpg

New Genuine Bonnet Front & Side Supports 

rs79.jpg

 

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Cables

New Genuine Handbrake Cable

rs82.jpg

New Genuine Clutch Cable

rs73.jpg

New Genuine Split Speedo Cable

rs74.jpg

New Genuine Accelerator Cable

rs72.jpg

New Genuine Bonnet Release Cable

rs75.jpg

 

 

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Engine & Gearbox

New Genuine Top Radiator Hose

rs65.jpg

New Genuine Lower Radiator Hose

rs65a.jpg

New Genuine Top Turbo Intercooler Hose

rs77k.jpg

New Genuine Lower Turbo intercooler Hose

rs65b.jpg

New Genuine Amal Valve

rs67k.jpg

New Genuine Radiator Fixing Kit

rs78.jpg

New Genuine Oil Filler Cap

rs71.jpg

New Genuine RS Turbo Distributor

rs69.jpg

After Market Sump

rs60b.jpg

New Genuine Timing Belt Top Cover

rs70.jpg

New Genuine Front Engine Mountings

rs70a.jpg

New Genuine Gearbox Mountings

rs70b.jpg

New Genuine Gearbox Selector Shaft Guides

rs92.jpg

New Genuine Selector Shaft Clamp

rs92a.jpg

New Genuine Clutch Pawl

rs73a.jpg

New Genuine Turbo Oil Return Hose

rs56h.jpg

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Fuel

New Genuine RS Turbo Fuel Tank

rs90.jpg

New Genuine Fuel Sender Unit

rs91.jpg

New Genuine Fuel Tank to Fuel Pump Hose

rs91a.jpg

 

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Boot

New Genuine Cab Rear Spoiler Fixing Kit

rs98a.jpg

New Genuine Boot Catch

rs13b.jpg

New Genuine Boot Support Strut (With Spoiler)

rs54a.jpg

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Well I had a few problems with pictures not showing on this post and with the new format of the site now making it much easier to add pic's I decided to up date this post and remove all the old comments

The pic's are now shown in groups of parts

I know this now just looks like a list of parts but the old post was all over the place

I hope no one is offended with me removing their replies but I will be leaving new replies for at least 12 months

 

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