Thanks for running us though the process Marty. That's some handy work.

Do you use polyester or epoxy Marty?
I'd be interested in knowing what you make.
Mk 2 Escort dash pad for example would be on my list.
 
Oh, the more I watch the yellow lugger progress, the more I could handle one quite easily.
(I'm picturing a  flat front 2l mk2, silver metallic, blue Cobra stripes, 15"minilights, bubble arches, rally pack front spoiler and bumperettes) 
More practical than the 4 door.

Hi Deano, I use polyester resin on my parts, it's cheaper and easiest to work with. Epoxy is for gear knobs and the like..
For mk2 dashtop there's a UK guy selling fglass copies that are 1st class, with all tabs and threads needed to install . Cost is about $250 from UK . I don't have a mold as yet for a mk2 dashtop 😞

Time to bring the interior dash parts back to original, taping up the black areas ready for silver pinstripes




Wired in a mega cheap radio($26) that looks period spec except it has Bluetooth, USB, SD card etc, I made speaker mounts to hide under the dash, one behind the glovebox and the other next to the bonnet release lever so the doors don't get molested !

Here's the dashtop after a few weeks of prep work

Nice work marty, ive been thinking of a retro radio myself.

I notice some sound deadening/insulation there, any hint on what you use? the only part of my floor insulated is the drivers side, thinking i might change that
 

Hello Robbie

The underfelt/deadener I used and thought to try it on the van is 10mm thick square sheets ,500mm x 500mm sticky back but not very sticky so it won't pull paint if need to adjust it. Chinese eBay 10 sheets for $45

To reduce engine/box noise from the tunnel is a trick I was told is to use 2x rubber gearstick boots under the console ..

I forgot to mention the radio also has a remote , not that it's needed in a small Escort lol

Got painting the door mirrors in satin black 2pk , I'm not a real fan of color match Ford mirrors


While I was in the shed I decided to machine off the castings on the steering boss, it lathed up to a decent shine

And to bolt to the boss kit is a cheapo Momo copy

Then I added red LED lights to the dash clocks, this dash was swapped in favour of a tacho dash but the effect is the same..

Looks nice Marty. Read all of this thread during the week. Hopefully mine goes as well as this one. Still got soo many bits to source. Resigned to the fact its not going to be a quick build. As long as it looks sweet at the end. Looks soo much better without the windows. Nice fix. Van looks the mutts nuts.

With the head all bolted down and cam dialled in with the newish adjustable pulley , manifold and 38DGAS Weber it was time to crank it over.. it started almost right away which was quite a shock as it takes a few goes with turning the dizzy.
Once the initial 10min @2500 to bed in the bottom end , I pulled the rocker cover off to reset the followers , with that sorted I hit the brake pedal and the motor stalled... Not good so I diagnosed the vacuum booster has a split diaphragm 😞, after measuring it's dimensions I found a hotrod booster on eBay for $85 , I went for the gold anodized version..

Not much difference between Escort and hotrodder booster , with the 4x mounting holes out by only 5mm and the rod was adjustable, things were easy to convert over


And this is the booster installed

Engine don't stall when braking now plus it looks nice, brake pedal is progressive and not hard. Remembering I'm using a Ford laser master with all STD brakes , time for road test..😁

Great looking van good work