My Orange Mk1 2door Project

Nice one ! Keep the pics coming

made some good progress

with the 5 speed, did you fabricate your own rear cross member? if so do you have any pics of it? interested in making another one? or 2?
thanks
Shea

Thanks Guys, i should be able to get some more pics up late tomoz or sat

I took the gearbox straight out of my old Escort, not sure what a cross member, if its the mounts that attaches the gearbox to the frame i alreay had one (of the other Escort), it looks like the original celica, the previous owner had just drilled a couple of hole in the floor pan and bolted it straight in. i think he might have widend the tunnel a little cause in the new car its a little snug so were going to expand it somehow or something [:x)], not quite sure yet but ill keep you all posted. ill look threw the photos and see if i have anything that my be of use, if you have anymore questions just ask

cheers

btw the sheds 9x24 (or something like that) so there should be enough room... already 3 Escorts [88][88][88]

Nope! he really wants other escy though, hes after a mk2 2door cause we haven't had one yet [:x)]

Thanks, it was lots of fun to fix... [:o)]

If my instructions dont make any sense, theres heaps of photos which should help, (btw my dad did it all, so yea credit to him)

1st - Removal
There about 12 or so welds around front acrh the heater bubble. There fairly easy to pick out, they arent as smooth as the area around them. To hard to explain, lucky i found a photo that might help
Download Attachment: Firewall Welds.jpg
101.38 KB
The welds are along dotted along the red line. To get rid of these we drilled and chisled and it seemed to work well... well we got it off

2 - Clean Up
We brushed back all the rust so there was only good metal left. So we knew what needed replacing and such. Also get rid of any bit of the heater bubble that break off cause off rust, as shown in pic below.

3 - Remove the Intake (circle bit)
Ours seemed to come off fairly easy with a cold chisle (or coal... i can't remeber what it was called). Try to keep the lop intact cause its needed for a template
Download Attachment: firewallpeice2.jpg
75.17 KB

4 - Cut bend Repeat
Cut out the bit that can't be used and need to be replaced. When cutting the new peices, several will be needed so shape nicely around everthing. after the shapes kinda right take it to the car and see what needs to be changed. bend it cut it down, repeat till its all good
Download Attachment: IMGP0618.JPG
66.57 KB
just keep bendin and cuttin, we used a mk2 door that we had for the steel.

Download Attachment: firewallpeice3.jpg
68.42 KB
Then the circly bit. We cut a long piece and bent into a circle and cut the indents.

Download Attachment: firewallpeice4.jpg
81.87 KB
Download Attachment: firewallpeice41.jpg
79.63 KB
All done!!... almost

5 - Weld
Weld all the way round all the gaps to make it sturdy and such. we didn't worry about making it completely water proof, we used ... um no more gaps? lol that kinda stuff anyway... but for cars
Download Attachment: firewallfinal.jpg
72.18 KB

6 - fill
To make it look all purty we filled bti round the front that would be seen, trying to keep it off the edge that it will weld or screw back on to.
Download Attachment: firewallpeice5.jpg
92.43 KB

we then under coated it and chucked some of the "no more gaps" style stuff on it.
Download Attachment: firewallpeice6.jpg
54.84 KB

My heater bubble bit was stuffed, we were going to try and fix it, but then thought why not use the near perfect one of my old car, cleaned that up a bit and good as new! Make sure you paint everthing, cause i think the reason they all rusted was cause they werent painted from the factory... were heaps of water goes and it wasn't painted [?]

were going to glue and screw it back on, so if we really have to take it off again it do able.

If you have any more questions im happy to answer

wow thats alot of work yaz are doing there !
It's coming together very nicely tho.

lol... camber's a bit whacked... [88]

*puts away his Mr State-the-obvious-Man costume*

really nice progress though. It's going to look great. I've painted my 1300 Kent the same blue... when I bought the engine it was a very old worn out version of that blue. It looks great and actually a chrome rocker cover with it looks really nice too. [;^)]