Hi All
I'm desperately seeking a rust repair section for the RS. I'm after a complete "C" pillar for bot sides to graft in the damaged inner and outer rusted sections rather than stick a plate over the outside. I understand these sections are about screwed on every 2 dr shell but hoping for a miracle.
See pic below for reference on the section I require.

 
Hi Paul,
Seriously doubt rust repair sections would be available.
The repair would not be a big problem to an old school panel beater who would form new sections and butt neatly and no one will ever know the repair is there.
The majority of the rust is only light surface rust and will clean up very easily.
There is no need to cut along the lower line you have marked that is parallel to the body line. Needs to come up much higher. The rear guards on the 2 door Escorts are long flat unsupported panels and will buckle easily. In the area you have marked will be only partly accessible to complete the repairs.
All that is needed is some 0.9mm sheet metal, a hammer and dolly, an angle grinder, a small mig welder, .....and patience. 

Yes Paul, have to agree with peterM in all his good advice

Peter, I'm not attempting to replace the entire section as marked but merely use it to donate the sections I need to replace. As you're aware there are 2 panels which meet which is where the rust begins and I was hoping to replace these pieces with the original profiles etc.
Looks like I'm in for a little more effort than I was imagining.

Agree with PeterM ,
A welder done a big patch on my mk2 escapee ages ago and the side panel pulled in nearly 1inch from heat warpage. .I sacked him and done a heaps better job myself !
Looking at the pillar and if any Narsty rust behind it I'd cut the pillar away to access it and once fixed weld the pillar piece back on using low heat while using compressed air to cool after the Weld . Always treat bare metal with a sealer to halt any rust starting again.
I'm actually working on a mk2 coup which has as new pillars So they still exist !
Good Luck mate

Hi Paul,
 
I am willing to talk you through the repair process step by step on the forum at the pace you are going. In as much detail as you need to be successful. This way it will take a little time but you will have the confidence to do a good job and learn something at the same time. And maybe a little bit of knowledge you can use sometime later on the next project.
 
I purchased a 2 door RS2000 18 months ago which was in very poor condition. Currently on a spit, recently bare metalled and undercoated. No hinged panels. The lower rear window corner is good which I can use as a reference with piccies to help talking etc.
 
What you have might look really ugly. With a little time and some basic garage tools, .....and patience, you will be amazed how the repairs can be very neatly done. Remember the area needing repair can't get much worse, so highly unlikely you will cause serious damage to the car if/when doesn't go right the first time. Be ready for a few attempts. Even the experts are mindful that the first attempt doesn't always work as planned.
 
 
 
 

OK - so the first step is to cut away the area around the damaged external panel to reveal what is behind? At this time the inner panel which backs this outer panel is also non existent - this is the extension of the inner drain from the vent (see below). I have already replaced the D/S boot recess with original panels since the image in my first post so I'm confident to do the work once I establish the method.

Good work Paul,
 
Sounds like this maybe a better way to go than using the cut out sections.
 
Good luck and keep the pics coming
 
Cheers,
 
Matt 

HI Paul,
 
Looks like you have done the hardest part already!
 
Re the air vent. Yes I would cleanly cut the c pillar outside panel away to just below the bottom of the air vent just enough to have a look/exploratory. Please post up a piccie. The cup at the bottom of the air vent is easy to replicate if needed.

My 2 door is in getting body/paint done at the moment. Bottom of both c pillars had a nice little rust section where water has been sucked in through the vents and then sits there with no where to go. My panel beater cut and replaced the damaged area and also incorporated a bit of pipe so that any water stuck in the bottom will drain through the hole into the boot. From there we are just going to run a bit of tubing down and out of the boot. It's a good idea for a common problem...