1994 - Ford Escort Cosworth - power steering fluid tank

Ah yep, that looks a fair bit wider from that perspective.
If your legs could go any wider they'd interfere with your brake anyway haha.

Nice socks!

I turned up some bosses to use to mount the foot rest

P1030417 by jono_misfit, on Flickr

welded in

P1030418 by jono_misfit, on Flickr

support bar fully welded in and dash re-fitted to make sure everything still clears and feels a good position.

P1030419 by jono_misfit, on Flickr

then the engine went back in

P1030420 by jono_misfit, on Flickr

sierras and escort cosworth gearboxes are held in with two little floating tabs in slots. Fine normally, but if your bolts loosen at all, there's a good chance on a rally stage it'll pull the tab out.

P1030421 by jono_misfit, on Flickr

Solution to this is to drill a hole through and bolt into boss on the gearbox tunnel

about here

P1030422 by jono_misfit, on Flickr

and here

P1030423 by jono_misfit, on Flickr

different positions either side as the mount is staggered

i need a boss something like this

P1030424 by jono_misfit, on Flickr

one boss, will go somewhere like here

P1030425 by jono_misfit, on Flickr

welded in

P1030426 by jono_misfit, on Flickr

Otherside was done as well

then started reassembing the spit

P1030427 by jono_misfit, on Flickr

P1030428 by jono_misfit, on Flickr

and removing everything from in the car again.

P1030429 by jono_misfit, on Flickr

P1030430 by jono_misfit, on Flickr

gone

P1030431 by jono_misfit, on Flickr

P1030432 by jono_misfit, on Flickr

this is to allow me to get back and clean back a few bits and pieces, a last few minor rust repairs, and seam weld the shell.

todays update doesnt look spectacular but was loads of effort and ferkin manky to do!

I went back to de-undersealing the car. This time I used a flexible wood cutting bit in the multi tool which just ploughed through it easily.

P1030433 by jono_misfit, on Flickr

P1030434 by jono_misfit, on Flickr

i then spent ages trying to get the seal sealer out of the joins so I could weld them. A combination of rotary wire brush, a normal wire brush, a scribe/pick, a cheap wood chisel (bough specifically for removing the underseal), some screw drivers , and a blow torch managed to get as much out as I could, but still not all.

P1030435 by jono_misfit, on Flickr

marked out some welds, because.... you know..... someone might look at it at some point

P1030436 by jono_misfit, on Flickr

then started stitching away.

P1030437 by jono_misfit, on Flickr

P1030438 by jono_misfit, on Flickr

P1030439 by jono_misfit, on Flickr

P1030440 by jono_misfit, on Flickr

P1030441 by jono_misfit, on Flickr

P1030442 by jono_misfit, on Flickr

P1030443 by jono_misfit, on Flickr

P1030444 by jono_misfit, on Flickr

still splattered a bit due to curse word in the seams, but I got a technique quite quickly of doing the first weld, then scrubbing out the burning seam sealer with the wire brush leaving the rest of the weld area clean to complete. I should have followed Mr Northerners advice and got the shell dipped thought. It was too expensive for me though.


Cleaned up and gave welds a once over with cheap zinc primer, to prevent any flash rust before I clean / paint the floor.

P1030445 by jono_misfit, on Flickr

then went into the car and started cleaning back some bits

P1030446 by jono_misfit, on Flickr

battery mount will go here

P1030447 by jono_misfit, on Flickr

having tested it before I welded in the drivers heal bar

P1030448 by jono_misfit, on Flickr

finished a few welds

P1030449 by jono_misfit, on Flickr

P1030450 by jono_misfit, on Flickr


I had my face mask on the whole day, but it needs replaced now as its getting difficult to breath through. definitely worth wearing for a job like this. I'll have to see if there are any for sale still but I think its not so likely.

You can partially clear the masks / filters by blowing them backwards with an airline, Its not ideal but better than nothing.

yep. its a mare clearing them out. I kind of assume its applied before they spot weld the panels together going by how far into the seams it is!

I went out back for a bit tonight and did some things.

holes made holier

P1030455 by jono_misfit, on Flickr

and it was at this point Jono_Misfit fudged up.....

bending the flanges

P1030456 by jono_misfit, on Flickr

P1030457 by jono_misfit, on Flickr

swaged in the holes.

P1030458 by jono_misfit, on Flickr

And it was was at this point Jono_Misfit realised he'd fudged up.

Basically I should have cut the centre row of holes out to 12.5mm, not 19mm. With the hole spacings i've used there isnt enough space top get the 19mm swaging die in without it crimping the edges of the adjacent holes.

its not horrific, the holes aren't really doing anything, and they will be under the battery when fitted. But i'll know they are there and wrong. I will see if I can live with it or if I need to remake it...

Planing for the best I trial fitted it and realised I needed another mod to clear a feature in the floor. The pressing in the floor for the fuel lines I think.

P1030459 by jono_misfit, on Flickr

will fit like so

P1030460 by jono_misfit, on Flickr

and the pressing it needs to clear

P1030461 by jono_misfit, on Flickr

it fits nicely

Some work to do on the captive nuts, and some swaged holes on the front face.

I bet that's annoying. Time to tig the donuts back in and then recut them?

added captive nuts and primed the under side

P1030480 by jono_misfit, on Flickr

the horizontal bolt side got a stiffener added first

P1030481 by jono_misfit, on Flickr

cleaned back the floorpan and welded in

P1030482 by jono_misfit, on Flickr

and started positioning new harness mounts.

P1030483 by jono_misfit, on Flickr

They still need welded in but i'm about to weld the other half of the underside so will do it then.

flipped the car over and continued on with the scraping

P1030484 by jono_misfit, on Flickr

and scraping

P1030485 by jono_misfit, on Flickr

main bit left to do is shaving this inner arch down and the front as well

P1030486 by jono_misfit, on Flickr


I also spent 30 mins walking round the car marking up and last bits that need welding.

Should get some progress on Sunday.

How you have the patients to photograph your work amazes me,but I'm glad you do.