1994 - Ford Escort Cosworth - power steering fluid tank

[jonomisfit]

i needed to turn the escort the right way up to get the rust out that fell up the cage leg. Whilst there I got the side windows out

P5114698 by jono_misfit, on Flickr

and then had a go at the screen.

P5114699 by jono_misfit, on Flickr

i bought these off ebay for about a tenner so wasnt expecting it to be very good. Plus most things i've read on the web said trying to get a bonded screen out without cracking is tough. My expectation were for a broken screen.

P5114700 by jono_misfit, on Flickr

but with time and patience it came out ok

P5114701 by jono_misfit, on Flickr

no cracks

P5114702 by jono_misfit, on Flickr

i mainly wanted the screen out to check there wasnt any rot developing in the inaccessible bits under the screen (which is a common escort rot trap) i was lucky.

P5114703 by jono_misfit, on Flickr

only a couple of minor scabs that had gone through (you see some with the whole area rotten out.

P5114704 by jono_misfit, on Flickr

this is the worst one.

P5114705 by jono_misfit, on Flickr

good to see ford did a nice design where all the panels meet nicely and don't leave water traps

P5114706 by jono_misfit, on Flickr

this normally gets a blob of seam sealer to fill it up

and decided as i'm here I should take the wings off for access and to check some more rot spots.

P5114707 by jono_misfit, on Flickr

this side looks OK so far (i've seen pics of one with a 25mm wide rotten gap)

P5114708 by jono_misfit, on Flickr

this side the outer skin has gone a bit at the hinge, but the inner skin is still solid after testing it with a hammer and screwdriver.

P5114709 by jono_misfit, on Flickr

after a bit of shaving back some underseal i got back onto the floor repairs.

steel

P5124710 by jono_misfit, on Flickr

adjusted to shape and welded in

P5124711 by jono_misfit, on Flickr

create the outer skin

P5124712 by jono_misfit, on Flickr

and weld it on.
P5124723 by jono_misfit, on Flickr

still needs cleaned back and some other welding to finish before I put the outrigger back on.

[skkylinedave]

Wow , interesting to how skinny the cages are compared to modern ones now.

[jonomisfit]

Should be the same. Main hoop is 50mm OD. Front legs are 45 and X bracing is 38mm.

[skkylinedave]

May 12, 2018 20:10:47 GMT jonomisfit said:

Should be the same. Main hoop is 50mm OD. Front legs are 45 and X bracing is 38mm.

I thought maybe its a group A one of something which had lesser specs  before WRC etc .
It just looks like the main hoop is the same diameter as the door bars etc.

[jonomisfit]

So you weren't wrong. I was out the workshop getting something last night and measured the cage.

The rear hoop is 50mm OD however when I measured the front legs they're 38mm od not 45 as I thought.

So it does have a fairly skinny old spec cage.

I shall have to consider what I'm going to do now. I'm not intending to rally it however if i was current msa regs say min 45 OD on main hoop and front legs so this wouldn't get a logbook.

I could cut out and replace the front legs but if I do that I might as well replace the whole cage.

I shall cogitate.

[Darkspeed]

May 18, 2018 14:59:26 GMT jonomisfit said:

So you weren't wrong. I was out the workshop getting something last night and measured the cage.

The rear hoop is 50mm OD however when I measured the front legs they're 38mm od not 45 as I thought.

So it does have a fairly skinny old spec cage.

I shall have to consider what I'm going to do now. I'm not intending to rally it however if i was current msa regs say min 45 OD on main hoop and front legs so this wouldn't get a logbook.

I could cut out and replace the front legs but if I do that I might as well replace the whole cage.

I shall cogitate.

G15's have log books with 38mm cages and My Strato's would be logbooked with 38 and 32mm dia - If the cage is a registered design with the relevant calcs you get a copy of the design sheet from the MSA for about £25 - this then gets used to assess against when being logbooked. It is only if its not a cage that has approval that it then needs to be built to the generic 45mm CDS in the blue book.

[jonomisfit]

Thanks for the info.

Unfortunately there's no manufacturer tag on the cage which makes me think this is bespoke. (Ignore the stickers they definitely aren't the manufacturer).

I've got no way of finding out who made it so going that route will be a challenge.

I might look into if I do a design that matches this can I do the calcs register it and legitimise it that way.

[keyring]

Just started at the beginning and made my way through this thread... Some amazing fabrication work, especially on the spit!
Definitely seem to have an awesome workshop!
And what an awesome car to have as a project!! Look forward to seeing more

[jonomisfit]

minimal progress on either of the projects this weekend, mainly its been spent digging out a raised flower bed to put a summer house in.

Anyway, grind back the welds
P5204726 by jono_misfit, on Flickr

position and re-fit the outrigger. This took a lot of adjusting to get it to fit right, and pushing up on the floor inside with a jack as the floor has been knocked up at some point.

P5204727 by jono_misfit, on Flickr

Its not the neatest looking one, but its in much better state now than it was.

primed as it might be a while till it gets cleaned up.

P5204728 by jono_misfit, on Flickr

I'm concerned about the rust at the bottom of the sill. Looking on the escort cosworth forum there are a lot with rusty bottom to the sills meaning rotten out mid sill. I'm concern at what mine might be like. Going by every other bit of the shell. Rotten is my expectation.

P5204729 by jono_misfit, on Flickr


i tacked on some box to stop the sill moving about too much... and did an exploratory cut

P5204730 by jono_misfit, on Flickr

It looks rusty here, but is actually in very good condition. The rust if from the piece i cut off. I am very very surprised.

P5204731 by jono_misfit, on Flickr

lightly cleaned up with the finger sander

P5204732 by jono_misfit, on Flickr


generally very good condition all the way along. when I used the mirror and the torch.

P5204733 by jono_misfit, on Flickr

Same cant be said for some of the flange on the other side of the central sill. That'll need cleaned up and replaced.

End of progress for a while. I'll be cracking on with the summer house so this is back in hibernation for a bit.

[jonomisfit]

whilst I was doing operation tidyup (see morris thread) I also took the chance to tweak a couple of bits on the escort body spit.

Not photo'd I adjusted the frame so I could get the pivot point closer to the centre of gravity for the shell. It now turns much easier so is closer. Ideally i'd have moved it even further but i was up against the strengthening webs on the spindle.

the other tweak I made was to add adjusters to the vertical arms so they can be raised / lowered easier.

P1044965 by jono_misfit, on Flickr

P1044966 by jono_misfit, on Flickr

P1044967 by jono_misfit, on Flickr

its not intended to hold the weight, just move the arm up / down to get the bolt alignment holes.

Much easier than the jack and wood i've ben using.

I may get a few bits done on this in the coming weeks.



Also, i should really paint the spit....

[Deleted]

Great to see this pop up.

[jonomisfit]

Even if i'm not doing anything else on this for a while, i need to sort this bit as otherwise i'll end up with a sill full of cack.

P1020001 by jono_misfit, on Flickr

some steel

P1020002 by jono_misfit, on Flickr

steel reduced in size

P1020003 by jono_misfit, on Flickr

mark up for the various holes that need to be drilled / cut

P1020004 by jono_misfit, on Flickr

drill / cut / fettle / prime

P1020005 by jono_misfit, on Flickr

weld in and clean up a bit

P1020007 by jono_misfit, on Flickr

i still need to dress the upstand

P1020008 by jono_misfit, on Flickr

All of this is under the side skirts, so i'm not looking for a hidden finish.

Some crud to cut out / replace on the inner sill to complete this bit.

P1020010 by jono_misfit, on Flickr

[jonomisfit]

Only time for a minor patch on the escort

cut back the rusty piece of inner sill back to the centre sill.

P1020012 by jono_misfit, on Flickr

Cleaned back and primed,

made a patch to go in

P1020013 by jono_misfit, on Flickr

clamped into position and welded it in

P1020014 by jono_misfit, on Flickr

P1020015 by jono_misfit, on Flickr

There were 7 off 12mm holes drilled in the floor for some reason (two were batter box, but other no idea however 12mm seems complete overkill for anything the floor could support).

So got some washers and welded them in to fill the holes. need dressed back still

P1020016 by jono_misfit, on Flickr

That was the end of progress. Will see what I tackle next time.

[jamesd1972]

Still making nice progress then, how much more hot work to do now ? Must have broken the back of it ?
James

[jonomisfit]

I'm starting to get there on the easy side.

The other side needs a lot more repairs.

[peteh1969]

Would it not be easier to buy a lower section of an escort and un pick the parts you need for the bad side rather than fabricating every part you need?

[jonomisfit]

I've got a new chassis leg and sill for the bad side so will be using them, or sections of them at least.

The main pieces that have rotten are Sierra derived. There are a couple of these up at the farm but there's no guarantees they're in any better condition as it's all normal rot spots.

Will see what needs a dressing once I start cleaning it all back.

[peteh1969]

Is it a genuine Escort Cosworth or has someone put a Sierra floor pan in an escort shell?

Please for give my ignorance I have had experience of the Sierra/RS500/Sapphire Cosworth but not the Escort so I'm not sure on how they were built (production line or side hall).

[jamesd1972]

From the factory like this with a cut down sierra Cosworth 4x4 chassis/floorpan (shorter wheelbase- diff to escort IIRC) with escort top stuck over it - Factory silhouette rally car  with inbuilt rust traps as designed to go rallying not last on the road as a result by the looks of it !
James

[jjeffries]

Am relatively new to R-R's, so with these updates this is the first time I've seen your thread; read the hole thing. Fantastic stuff, both the rotisserie construction and the main feature, the unibody restoration. Thanks for taking the time to share it with us. John, Connecticut, USA.