The exhaust system came with headers that were in good condition, all I done was rough off the rust and have the system a squirt over with silver heat paint . Also I bought 2x sets of flanges and a flex pipe welded just behind the headers collector .



I bought a hotdog muffler to go at the back which is only to reduce crackle and there's not much back there to fit a good size backbox .



Got the head back and bolted it to the block



Things should move faster now

Bit of a gap last month between posts as I decided to make the bonnet for the vans previous owner... The bonnet is mk2 escort.
Here I'm sticking sides on from cardboard so it'll become a 3 piece mold and easier to make and crack/remove out the mold.

After the release agent dried I brushed on the blue gelcoat

5 layers of csm and some half tube to help strengthen the frame, waiting a week to dry thoroughly

I made the sides and back with the original return edge to replicated the original bonnet

Next was to prep the hinge mounts, cross brace and front slam which will use original latches etc, this pic is only gelcoat but the process is the same but less material layers was used.

Once the mold was cured I carnuba waxed it 4 times to
make sure it's fully covered and won't stick, this time the gelcoat is orange!

3x layers of 450 Csm was then applied and was let dry

Once the cross brace parts are trimmed and has nuts and studs installed I then lined the pieces up with measurements from the original bonnet and was then glued into place and lightly weighted down till it's fully cured


And that's the life of making mold and part, I forgot to take a finished pic, after so long working on it I don't really think to stop for pics, it ended up weighing 3.7kg..

You need to make RS bonnets Marty as they’re HEAVY!!

I agree, that's why I had so much fun getting gas struts to work on my Bonnet!!
Cheers, Len

You make it look so easy Marty, I like your build up pictures of the bonnet, looks like a nice piece of work. 

Haha, that's why RSs are 100kg heavier than flat nose Escort due to the front end hang ons .

Paul, donate you bonnet and I'll fglass copy it. When I used to make them at Velo seats/Quickco they weighed about 4kg.. Much better than 17kg? of a real one !!
I can understand why Len went gas struts !!
Blue74 , its is easy to make although it's the preparation that takes all the time 👍

Maybe before it was painted Marty 🙄

Hey Marty, plan on offering them for sale? I've always liked the idea of a lighter bonnet, but would only consider it if it used all the factory hardware, as I don't want bonnet pins.

'Maybe before it was painted Marty 🙄'.
I understand Paul. I usually paint parts in 2pk before taking a mold as it doesn't react to the resins.
Flighter, I make all my parts to replicate original fixings, ie hinges, locks etc... Unless someone just wants a skin only panel..
I'm in the process of updating a list of my parts /panels , the bonnet will be about $450 complete ..