1994 - Ford Escort Cosworth - power steering fluid tank

I'll find out soon enough.

10 days turned out to be 1 day. In the post and here tomorrow!

Still blows my mind every time this thread appears on page 1, how much rot you are having to tackle. And doing a great job of it you are! 

I mind looking under an Esc Cos that was for sale at Ford Fair for good money and it was visibly hanging underneath. Esp at the  rear axle mount.

Still my all time dream car though! When asked the lottery win question it remains my answer. 

what blows my mind is how the RS brand, the social history, the culture makes the cars worth twice, three times as much as equivalent sporty models from the other makers. its not because the cars are three times better ! (not meant as an insult, but you know what i mean)

people on facebook groups might share a picture of a rotten 16v astra they saw in a bush, or breakers yard. then you get all the comments from people like "shame" "worth a fortune that". then i reply saying yeah about 8k after you've sunk 10 into the resto

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.

Lets hope you don't have to remake 90% of it to get it to fit?

The outer edge of the floor may well be correct for a sierra, this was the area which was modified to join a sierra floor pan to escort sills.

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.

What are all the slots in the floor panel meant to be for?

Ok

Well if they are for the E-coating they don't work or it would not of rusted so bad.

They do seam a bit of a waist.