Hi everyone, been chasing leaks in my mk2 2 door. Found I had water coming in through the drivers side A pillar (some panelbeater had blocked up a drain hole at the bottom of the guard so the water would collect with dirt that built up through the years and leak through to the inside), and from a rusted area where the heater bubble attaches to the firewall.
 
I have solved the A-pillar issue by drilling the drain hole and converting the rust, however the heater bubble area needed more attention.
 
Here are a few photos of how its gone down:
 
When I got the heater bubble off it looked like this:

 

 

 

 
Made a patch for the bubble itself

 

 
Brushed rust converter EVERYWHERE

 

 
And now sorting out how it all will fit back together

 
Next job is to weld in this repair section where ive got my big rust hole

 
 
I am jumping into this head first with advice from a mate who has repaired many cars before, a rust repair book and common sense, however no amount of help is ever enough.
Anybody with opinions or advice or constructive criticism please let me know what you think, keen to do this the correct way the first time.
 
Thankyou in advance,
Ryan

You are doing really well with the motor still in the car, going to make firewall repair from the inside the car uncomfortable, but can be done.
Good work

Hi Ryan,
 
You are doing a great job there.
 
I am doing something similar to an RS2000 being restored at the moment. For future maintenance the large round hole has been opened up to a square to gain full access to inside the bubble from inside the car after the car is fully assembled. At the moment working on best method to re-attach the scuttle/grille panel so that can be removed but must not be seen otherwise will devalue the car.
 
Happy to put up piccies if you wish.

 
 

PeterMFor future maintenance the large round hole has been opened up to a square to gain full access to inside the bubble from inside the car...

Surely the heater fan will not be all that effective as rather than pulling air from outside the car it will partially pull air from inside the heater box?  The shroud is there to ensure the fan pulls outside air only...same as the shroud on a radiator fan.  Just a thought.
 
PS - I converted my bubble to  bolt on, via some rivnuts, to achieve maintainability

Thanks for the replies so far
 
Thanks JVC063, it is a bit tricky trying to bend my body around and work inside but im making do. Scared that if i take the motor out i wont have the motivation to get it done as quick.
 
Photos would be fantastic thanks Peter, cheers.
 
I was going to reattach the bubble via welds however was thinking about extending the drain hole to the base of the bubble. Factory design apears to always leave a little bit of water in there to collect. Also would get rid of the little flange directly below the drain hole to prevent water sitting there.

 
I have another couple of good ideas (i hope so) I will post pictures of tomorrow.
Hoping im able to keep progressing at this rate around uni.
 
Cheers,
Ryan

Tried to upload these last night from home.
 
Here is images of a Mk1 Escort replacement panel for under the bubble available through me.
 
I am currently in production of a Mk2 Escort panel as well, I have a couple of prototype already made.
 
They are $275.00 on ebay  , on here will be $250.00 as there is no fees on here.
 
call Jim 0407896015
 

 

 

Looking good Ryan...... I put this job off until to get a bit more practice with the welder but it wasn't as bad as I first thought. The firewalls a lot better than mine was, shouldn't be to hard to weld a patch in there, you'll loose the little indent but its hidden by the engine and the price of a new firewall from ex-pressed is truly scary....
Good luck with it, keep the pics coming.....
cheers Drew.

"Surely the heater fan will not be all that effective as rather than pulling air from outside the car it will partially pull air from inside the heater box?  The shroud is there to ensure the fan pulls outside air only...same as the shroud on a radiator fan."
 
The original thin rusty steel including the fan shroud is completely replaced with stainless steel exactly the same design as what Ford did.
 
I will find the photos and put them up asap.

I made my hole like a mouse hole as you have shown, it is not noticable when you put the rubber flap back on.
John