1994 - Ford Escort Cosworth - power steering fluid tank

A lot of the VW air-cooled repair panels don't fit as well as they used to. I was told that the dies had been spec'd for a certain number of pieces and had then worn out as they'd kept on being used. Unlikely to be the same problem for the EsCos or Corvair though!

Yep, Gerson has spent a lot of time and money on the funky green panels, especially for early cars. Autocraft from the UK, Wolfparts from Sweden and Virtanen from Finland are also excellent. I heard that Virtanen cut apart his own original unwelded oval beetle to measure the rear crossmembers accurately!

Brilliant work mate nice to see it being done right and I'm not the only one moaning on about shocking panel fitment !!!!

Not great progress today, I've got major tooth ache and really struggling to get much motivation.

I eventually dragged myself outside hoping it would distract me.

plug welded the chassis leg from inside

P1020171 by jono_misfit, on Flickr

This is the end of the diff beam cross-member that needs sorting and re fitting

P1020169 by jono_misfit, on Flickr


the black line shows whats solid and whats rotten

P1020170 by jono_misfit, on Flickr

Its got quite a bit of shape to it that will be a nightmare for me to replicate, so trying to retain some of it.

Trim and will go back here

P1020172 by jono_misfit, on Flickr

start trimming up a piece of metal to fill the gap

P1020173 by jono_misfit, on Flickr

fettle clean and weld in

P1020174 by jono_misfit, on Flickr

I also bent up a piece for the side strengthener and welded it on, as well as welding the brake pipe holder back on.

P1020175 by jono_misfit, on Flickr

P1020176 by jono_misfit, on Flickr

gave it a once over with the uber primmer

P1020177 by jono_misfit, on Flickr

and then got back on with shaving more of the floor

P1020178 by jono_misfit, on Flickr

P1020179 by jono_misfit, on Flickr

I found sharpening a flat blade in the multi tool shaved off the underseal nicely.

That was the end of it for today. Hopefully more sorted next weekend and get something done on this and the morris.

So some brakes came up for sale vaguely near me, and i needed a set. Fatboy DW helpfully picked them up for me.

Trial fit to see what they'll be like.

P1020180 by jono_misfit, on Flickr

P1020181 by jono_misfit, on Flickr

P1020182 by jono_misfit, on Flickr

hopefully they'll be enough to slow the car down...

If anyone is thinking, they look big... they are.

P1020183 by jono_misfit, on Flickr

355mm disks. I thought it'll all weigh quite a bit, but I was surprised. I'm not sure how much heavier they'll be than standard. As the standard kit isnt light.

before I can tackle any more of the rust I need rid of the seat mounts and this stupid box that's been welded in .

P1020184 by jono_misfit, on Flickr

this looks fairly straightforward to get off, but it wasnt. Lots of hidden welds.

P1020185 by jono_misfit, on Flickr

surprise, lots of rot. lots and lots of rot

P1020186 by jono_misfit, on Flickr

i ran out of cutting discs at this point, and rather than waste time on a trip to Screwfix I moved onto the morris.

P1020187 by jono_misfit, on Flickr

When you see the way this has all been put in, its no wonder there's a lot of rust on the escort. Induced by the..... interesting way some of the mods have been done and failed to be protected.

You can also see the state of the door bar that someone butchered out, using what I can only assume was an angry badger. This will be getting replaced.

I also quickly inspected under one of the floor patches

P1020188 by jono_misfit, on Flickr

which, whilst not amazingly done, wasnt the worst that was on the car

P1020189 by jono_misfit, on Flickr

except... no attempt had been made to remove the rusty floor from under the patch.....

P1020190 by jono_misfit, on Flickr

and when I peeled back the other patch

P1020191 by jono_misfit, on Flickr

oh look, the cage footing hasnt even been welded to the new plate. But the gap has been nicely closed with structural seam sealer.....

Some people seem determined to kill themselves, or some bodgers doing work for people seem determined to kill their customers...

I've enjoyed working my way through your recent updates, bookmarked this so I don't miss them again.
Unreal the amount of rust you keep finding, but your repair work looks great! Certainly don't hang about!

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.

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.

Or an even louder stereo and a lock workshop door could help.