1994 - Ford Escort Cosworth - power steering fluid tank

[jonomisfit]

shot to show relationship of seat bolsters to foot rest

20200413_194058 by jono_misfit, on Flickr

20200413_194105 by jono_misfit, on Flickr

when sat in the seat (with big clompy (knackered) size 11 work boots on)

20200413_194125 by jono_misfit, on Flickr

quite a bit of space to move feet round

when sat in the seat it difficult to have anything other than legs straight ahead due to the bolsters. This is my attempt to spread knees as wide as possible, and its really uncomfortable from seating position. I think your legs will naturally tend to straight out, bent at the knee.

20200413_194132 by jono_misfit, on Flickr

[varelse]

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!

[jonomisfit]

thanks. That was my tame pair of socks :-)

welded the seams

P1030403 by jono_misfit, on Flickr

folded a bit

P1030404 by jono_misfit, on Flickr

bent up some 6mm ali rod

P1030405 by jono_misfit, on Flickr

tacked it in

P1030406 by jono_misfit, on Flickr

started dressing it

P1030407 by jono_misfit, on Flickr

dressed, folded, welded

P1030408 by jono_misfit, on Flickr

P1030409 by jono_misfit, on Flickr

P1030410 by jono_misfit, on Flickr

pretty lightweight, and pretty stiff

started trimming a piece of box to act as the footbrace support

P1030411 by jono_misfit, on Flickr

hmmm... the works cars all had much lightness added. Better add some.

P1030412 by jono_misfit, on Flickr

swiss cheesed nicely.

Hmmmm

this looks a bit plain

P1030413 by jono_misfit, on Flickr

I wonder

P1030414 by jono_misfit, on Flickr

much betterer

P1030415 by jono_misfit, on Flickr

looks much more rally car now :-)

P1030416 by jono_misfit, on Flickr

Just got to sort the bosses for the base, then weld it all in.

[jonomisfit]

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.

[ian911]

You have been busy, nice update.

[jonomisfit]

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.

[jonomisfit]

Speaking of battery mount, I figured I needed to start making one.

I designed something that replicates the WRC battery mounts

Battery Mount Assembly - side view by jono_misfit, on Flickr

Battery Mount Assembly angled view by jono_misfit, on Flickr

Battery Mount Assembly - front view by jono_misfit, on Flickr


Battery Mount Assembly - brackets by jono_misfit, on Flickr


But figured this is just overkill. I'm not competing on gravel rallies so i'm not too worried about a big bolder smashing up under the battery and killing it.

I decided to go for something more like used in a subaru WRC, seen here hiding behind the drivers seat. Extinguisher on the co-driver side.

WRCshellSGM11thFeb2008148 by jono_misfit, on Flickr

(Someone elses pic, all credits to them)


A hand sketch

P1030451 by jono_misfit, on Flickr

some steel

P1030452 by jono_misfit, on Flickr

marking out

P1030453 by jono_misfit, on Flickr

pilot holes drilled

P1030454 by jono_misfit, on Flickr

...and ran out of time

[kevins]

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

[jonsey]

I spent last week seam welding my nephew’s Astra GTE that I’ve been turning from an Autograss car into a stage rally car. It’s amazing how far the sealer gets into those seams. And if you don’t get it all out it’s like welding with no gas. Fantastic build by the way.

[jonomisfit]

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!

[Deleted]

Apr 18, 2020 19:56:24 GMT jonomisfit said:

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!

Probably not in the era that this shell was built in but almost certainly now the vast majority of vehicle bodyshell assembly lines use a bonding sealer that can be spot welded through - the stuff that you and jonesy are finding that was applied in the 80's / 90's as a semi liquid creeping sealer at the factory - that's why the rally car builders send their brand new bodyshells for dipping to remove all traces of any paint & sealer from the seams but they will be a day in the future when they can no longer do this due to the fact that more vehicle producers are turning to bonding technology rather than relying upon a welded process - put one of these shells in a oven then dip it and it will just fall apart

[jonomisfit]

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.

[jonomisfit]

I really need to tidy the bench.

[varelse]

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

[bstardchild]

Apr 19, 2020 20:39:52 GMT jonomisfit said:

I really need to tidy the bench.

At least you can see yours - I can't see any of mine

Yeah lockdown tidy up in progress

[jonomisfit]

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.

[jonomisfit]

today was a dirty day. Dirty dirty day.

much shaving, scraping, and buffing with the wire wheel got the underseal off

P1030487 by jono_misfit, on Flickr

cleaned out the seams and welded

P1030488 by jono_misfit, on Flickr

then on to the front end for the same treatment

P1030489 by jono_misfit, on Flickr

and stitched

P1030491 by jono_misfit, on Flickr

P1030492 by jono_misfit, on Flickr

P1030493 by jono_misfit, on Flickr

i cleaned up the seams on the rest of the side as best i could, and marked out for welding.

P1030494 by jono_misfit, on Flickr

P1030495 by jono_misfit, on Flickr

the stitched away

P1030496 by jono_misfit, on Flickr

P1030497 by jono_misfit, on Flickr

P1030498 by jono_misfit, on Flickr

P1030499 by jono_misfit, on Flickr

then turned my attention to the remaining bits inside the car

P1030500 by jono_misfit, on Flickr

P1030501 by jono_misfit, on Flickr

stitched the internal cross beams

P1030502 by jono_misfit, on Flickr

and round the wheel tubs

P1030503 by jono_misfit, on Flickr

P1030504 by jono_misfit, on Flickr

then went round the engine bay cleaning back and stitching any seams that hadnt already been done

P1030505 by jono_misfit, on Flickr

getting into the seam at the back of the bulkhead was a pain as it was a long reach and I couldnt get my head anywhere near.

P1030506 by jono_misfit, on Flickr

there's a few more bits to do / tidy up, then it'll be onto clean down ready for treating any rust.

[ian911]

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

[teaboy]

Apr 30, 2020 18:18:42 GMT ian911 said:

How you have the patients

I know that he’s doing plenty of surgery on his car but I didn’t realise that he was a doctor.

[jonomisfit]

Apr 30, 2020 18:18:42 GMT ian911 said:

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

If I'm doing a job and have to walk to the bench then I use that to pick up the camera

Plus at the end I want to have a full record of what I've done. I can turn it into a book for me, or a YouTube video with dodgy music 😁