I would like to ask the experts here if there are any big issues with using a Mk2 floor pan (front to rear), sills maybe(?), with a Mk1 complete upper bodyshell?
 
I am evaluating producing new Mk1 shells, and I can buy new Mk2 floor pans that already exist, and if they are usable, that would majorly cut the cost of making them.  
 
I even remember in the day, Ford advertised an old Mk1 and a new Mk2 rally car shells with all the bits laid out saying that one could swap all the Mk1 stuff into the Mk2 ... 

To simplify matters, the whole floor from bulkhead to back panel is the same, even the A post splash panels swap over, I've used either for both models. All I've noticed is the chassis rails are slightly wider at the leaf spring mounts for mk2.
Mk2 sills are different to mk1 being the door opening for mk2 is longer and wheel arch shape differs between models. How this info helps..

martymexico
To simplify matters, the whole floor from bulkhead to back panel is the same, even the A post splash panels swap over, I've used either for both models. All I've noticed is the chassis rails are slightly wider at the leaf spring mounts for mk2.
Mk2 sills are different to mk1 being the door opening for mk2 is longer and wheel arch shape differs between models. How this info helps..

Thanks Marty, that's the sort of info I was chasing, appreciated.
 
What do you know about the front inner arches and front rails? I believe the X-members interchange so must be of similar foundation/pickup points even though not identical?  

I guess I am also simply asking is this an acceptable, Mk1 but with the minor(?) differences of a Mk2 underneath?
 
It's just that it literally halves the development cost of making Mk1 shells, and of course that makes them cheaper to sell.
 
 

Mk2 front rails are very similar to mk1, except mk2 have some crumple zone creasing behind the swaybar mounts, and all bolts went to metric where fitted.
Inner wings do fit but some welding where the guard rail is will need relocating inwards, strut strength plates are bigger on mk1 and mk2 inner wings have been moulded with a bigger battery slot both sides. Lower Radiator support panel is different between models as well ...

What most of us mk1 owners do is replace running gear and suspension bkts etc from a mk2 so if you use a mk2 chassis, inner wings( for more engine bay space) and other parts, it'll be better for everyone

Marty is on the money as usual .
You can buy mk1 floor pans quite easily and there is a number of companies now in the UK producing full new mk1 and mk2 body shells from tried and tested tooling but if you have the capability and resource to produce the panel dies I would be interested to see the results..
I  am in the middle of becoming the Oz dealer for www.mst-cars.com but I would love to see a local version 

That's pretty full on Bonus, good luck with the projetc.
Does that mean you may look at holding Aus MST parts as well?

It is something im thinking about Deano and the deal is already in place , im just not sure there is the demand to warrant stocking here . 
I already supply a number of guys in oz with bits but ship it over with items i import for another business , this cuts freight massively which is usually the killer . 

Thanks guys, much appreciate your inputs!
 
Bonus, you might like to know that we are looking at supplying Gp4 prepped shells, can't see any reason to supply stock shells when most are converted at extra expense anyway, why not do it up front.
 
Anyway, early days, let you know later what we are getting up to.