jonomisfit
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Jul 10, 2019 16:24:31 GMT
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I've never been 100% certain, but assume it's for the e-coating process as they get filled by foam sealant and covered with sound deadening pads, so can't see then having any use in service.
Most repairs in this area people cut them out and plate them solid.
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jonomisfit
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Jul 10, 2019 12:39:52 GMT
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today was this morning only out on the car. interior piece welded in P1020465 by jono_misfit, on Flickr and the plugs done from external then cleaned back P1020466 by jono_misfit, on Flickr this is the section behind the cage leg pre-clean up P1020467 by jono_misfit, on Flickr cleaned back, rust killer applied, then a coat of Uber zinc primer. P1020469 by jono_misfit, on Flickr infill plate made P1020468 by jono_misfit, on Flickr and welded in P1020470 by jono_misfit, on Flickr P1020471 by jono_misfit, on Flickr I've a few other rust repairs to do, then it'll be clean back, trim, and fit the floor. It already looks like the depth of the front section will need to be reduced to get it to meet all the required points.
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jonomisfit
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Marked up a rough cut location P1020440 by jono_misfit, on Flickr drilled out the accessible spot welds P1020441 by jono_misfit, on Flickr P1020442 by jono_misfit, on Flickr and used the ball end carbide in the angled die grinder to get the less accessible ones and peeled back the lip P1020443 by jono_misfit, on Flickr then zipped along the cut mark P1020444 by jono_misfit, on Flickr to give me a full on Flintstones mobile P1020445 by jono_misfit, on Flickr that doesnt look promising P1020446 by jono_misfit, on Flickr actually, the mid sill is in good condition, a couple of minor repair spots needed, but generally just a clean and paint required P1020447 by jono_misfit, on Flickr P1020448 by jono_misfit, on Flickr and the floor pan put in position P1020449 by jono_misfit, on Flickr it touches at the required points P1020450 by jono_misfit, on Flickr a few adjustments needed P1020451 by jono_misfit, on Flickr a bit of shortening required P1020452 by jono_misfit, on Flickr if you compare the next two photos you can see a few differences in the pressings. I think they are mainly to do with the differences between 2wd and 4wd floor pans (this is a 2wd floorpan as 4x4 are not yet available) P1020449 by jono_misfit, on Flickr P1020440 by jono_misfit, on Flickr It may look slightly different, but it'll still work fine, so it it shall go. But first, there are a fair few other bits to sort out. Like this suspiciously crusty bit under the cage foot. P1020453 by jono_misfit, on Flickr to access it though, this needs to come out. X marks the spot weld spots P1020454 by jono_misfit, on Flickr It does mean i'll be able to straighten out the damage to it from all the badly placed jacks.... as expected, a large hole under the cage foot, just like the passenger side had P1020455 by jono_misfit, on Flickr P1020456 by jono_misfit, on Flickr I cleaned it all back to solid metal, but forgot to take a pic The jacking point looks disgusting here, but its body wax and is generally in good condition P1020457 by jono_misfit, on Flickr there are also some rust spots on the tunnel that need addressing. black line is where the floor joint will be made. P1020458 by jono_misfit, on Flickr some of the rust spots are above the intended cut line. However it needs to be there as wider that this the trans tunnel section is different due to the 2wd floor pan. so trim back and clean further, patch it, then cut and weld the floor to this point. P1020459 by jono_misfit, on Flickr cleaned back metal is all solid, and a good point to work to. P1020460 by jono_misfit, on Flickr patch piece made, and clamped to check it'll fit P1020461 by jono_misfit, on Flickr making the reinforcing rib on the curve was a pain! P1020462 by jono_misfit, on Flickr cleaned and primed ready for welding P1020463 by jono_misfit, on Flickr P1020464 by jono_misfit, on Flickr that was it for today. I may get a bit of time on it tomorrow.
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jonomisfit
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That may be the case, but I'm more inclined to think it's either a 2wd vs 4wd change or more likely an Express panels convenience thing as this way they can fold the edge rather than press a very detailed shape in.
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jonomisfit
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Shape wise it looks like it'll fit ok.
As it's a rwd Sierra pressing some of the details are different so I need to be careful where I cut.
Pics up later. Currently have an escort rs cosworth flintstones special..
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jonomisfit
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I was away for the weekend and got back to this lying in the middle of the drive.... 20190708_152255 by jono_misfit, on Flickr thankfully all was OK when I opened it. 20190708_152622 by jono_misfit, on Flickr 20190708_152633 by jono_misfit, on Flickr Hopefully get chance to check it out properly tomorrow. I have noticed this edge isnt right v's the factory panel. 20190708_152641 by jono_misfit, on Flickr the factory panel has a 5mm wide 45 degree offset on the top edge, whereas this is just folded square. it also feels thicker metal v's the factory stamping, but will check it tomorrow.
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jonomisfit
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The pics are great and a shame to see them come to an end.
For me RR has just got to the point that there are too many threads with too many good and interesting things on to have any hope of keeping up with them all or providing feedback/ comments.
Motivation to persevere with a thread has to come from within, as often people enjoy the content but don't feedback.
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jonomisfit
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Agreed. Completely over priced. Completely.
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jonomisfit
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Today was mainly spent marking out, a lot of it, like tons... Marking out P1020424 by jono_misfit, on Flickr start drilling some terminus points P1020425 by jono_misfit, on Flickr and start trimming using the air shears P1020426 by jono_misfit, on Flickr rough trimming P1020427 by jono_misfit, on Flickr mark out the majority of the holes and drill the centre P1020428 by jono_misfit, on Flickr this is where the shape starts deviating from the drivers seat, trim in the trunk reliefs P1020429 by jono_misfit, on Flickr start bending some of the flanges P1020430 by jono_misfit, on Flickr start the major folds P1020431 by jono_misfit, on Flickr I've also marked out for the cage clearance hole P1020431 by jono_misfit, on Flickr start the side folds P1020432 by jono_misfit, on Flickr I'm not sure you can see easily, but compared to the drivers this is a more vertical hip / thigh support which then bells out part way up. P1020433 by jono_misfit, on Flickr cut the cage relief hole, then folded the shoulder support wings P1020434 by jono_misfit, on Flickr again these are bent further round than the drivers side P1020435 by jono_misfit, on Flickr very roughly thrown into position P1020436 by jono_misfit, on Flickr P1020437 by jono_misfit, on Flickr an indication of how much lower the passenger is, it about 150mm further down. P1020439 by jono_misfit, on Flickr the passenger seat will also be reclined back at a slight angle. Next session will be adjusting it to fit better in the hole.
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jonomisfit
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Yep, you can guarantee a lot of the 25k escort cosworths are rotten underneath.
Its interesting looking at the projects section if the escort cosworth forum as there are a lot of very substantial repair for rust. Forum is probably owners only for that reason.
Mines in fairly good condition compared to a number of them. Most of my rot is caused by poor protection after the cage etc were fitted.
My favourite too, hence having to get this when it came up, even though I've got the Morris to finish.
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jonomisfit
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I'll find out soon enough.
10 days turned out to be 1 day. In the post and here tomorrow!
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jonomisfit
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Me too. I can't see it being a worse fit than the chassis leg though!
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jonomisfit
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...jonomisfit
@jonomisfit
Club Retro Rides Member 49
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Stunning as always
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jonomisfit
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Mrs_misfit wanted peace in the summer palace so I tidied the workshop a bit, contemplated for a while, then decided to make a start on seat no.2 as it was quiet work. start with the template P1020418 by jono_misfit, on Flickr mark some lines P1020420 by jono_misfit, on Flickr mark some more lines P1020421 by jono_misfit, on Flickr and some more P1020422 by jono_misfit, on Flickr and some more P1020423 by jono_misfit, on Flickr some slight changes to the seat v's the drivers one, to sort it being lower, to give some extra space for a wider range of passengers (about 35mm wider on the base), and to clear some other obstacles the other seat didnt have to. Will see how it goes.
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jonomisfit
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having decided to order the floor, that put me into a bit of spin as to what to hit next on the escort. So decided to do a few bits in prep of when it arrives / removing the old floor. Feet doubler plates on this side look a bit suspect. get out the trimming tool P1020413 by jono_misfit, on Flickr that looks properly manky.... P1020414 by jono_misfit, on Flickr wait, whats that? it looks like... it almost looks like some cowboy has left the sound deadening in there and has put the strengthening plate over the top..... chip off the sound deadening and the important bits are in pretty decent condition. P1020415 by jono_misfit, on Flickr P1020417 by jono_misfit, on Flickr I'm assuming it was left to act as additional padding.... removed the passenger seat mounts, as I have a proper seat rail kit to fit P1020416 by jono_misfit, on Flickr At this point Mrs_Misfit wanted to use her summer palace, so noisy tools were put away.
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jonomisfit
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Half floor ordered, but its 10 day to dispatch.
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jonomisfit
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Visibility is surprisingly ok...ish, but I suspect parking will be fraught with concern as you have no idea where the exact front is.
Thanks. I can see there being a lit of tweaks to seating position once the thing is mobile.
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jonomisfit
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March! That seat took a bit longer than i thought..... Where was I? oh yes, rust. cut cut cut.... grind grind grind floor based ventilation system P1020408 by jono_misfit, on Flickr I used the die grinder with carbide burrs to get rid of some of the multiple layers of welds that had previously been applied.... P1020409 by jono_misfit, on Flickr P1020410 by jono_misfit, on Flickr rust killer applied, then primed, then welded in the first set of patches. P1020412 by jono_misfit, on Flickr I've contacted express-panels to see if they have any half sierra floor pans in stock. Looking at the amount of patches it'll be quicker putting in half a floor rather than sorting individually. Will see when they get back to me.
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jonomisfit
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Right, on with trying to make this less ugly. mark out a template, make it more awkward by starting in one place with one colour pen, then changing place and pen colour.. P1020393 by jono_misfit, on Flickr turn into a template P1020394 by jono_misfit, on Flickr turn into steel P1020395 by jono_misfit, on Flickr roughly in position P1020396 by jono_misfit, on Flickr weld on P1020397 by jono_misfit, on Flickr then neaten up this bit. card P1020398 by jono_misfit, on Flickr steel P1020399 by jono_misfit, on Flickr swaged and welded steel P1020400 by jono_misfit, on Flickr bolted in P1020401 by jono_misfit, on Flickr bit of clearance here for a bit more space in an side hit P1020402 by jono_misfit, on Flickr not so much here P1020403 by jono_misfit, on Flickr it is absolutely rock solid when bolted down, and the seat is super stiff. in terms of where you sit P1020405 by jono_misfit, on Flickr Whilst its not a normal sitting position, its not that uncomfortable P1020406 by jono_misfit, on Flickr Looking at it, passenger seat will sit down here somewhere P1020407 by jono_misfit, on Flickr But that can wait for a bit, as I fancy a change of projects for a while.
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jonomisfit
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Jun 21, 2019 20:01:23 GMT
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look ssstunning so far
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