Bit of an update, cut the section out where my heater bowl repair section will go and marked where I need to fassion a firewall repair section


 
 
Thanks Jaycees that looks like a very handy reproduction, ill have to pass on it though as mine isnt too bad in the top section where the fan pokes through. Also I will make a new fan shroud and install it last, letting me have hand access into the bubble from the inside to properly seal the seam.
 
Cheers Drew, yea ive got a mate who knows a panelbeater who may make me a cut-out as ive marked in white, but i reckon its just as easy for me to cut a flat section. It's not going to be a concourse car so dont see the need to keep that little indentation.
 

PeterM
I will find the photos and put them up asap.

Thanks Peter
 
Ok thats good news thanks John. Still a tad undecided on cutting it though.
 
So here is my wonderful (possibly) idea:
If I was to run a small diametre plastic pipe from where the bottle top is positioned, the water would all drain out. I could run it inside the car then out on the top of the trans tunnel. This would be covered by both the heater and carpet when installed. And let me keep the heater bubble looking standard.
 


 
What are your thoughts on this and has anybody fitted a drain as I explained? Would be very straightforward to make up.
 
Cheers,
Ryan

While I'm not a fan of internal drain holes and piping I do think there is some merit in extending the bubble opening as you have pictured above to eliminate the water retaining ridge.
Mine is slightly different but seems to work OK .. as pictured.
GG.

Thanks GG thats food for thought. I was leaning towards the drain as I would like to retain the original image of the car but having said that, your drain looks fairly inconspicuous. Also it would make for a harder job putting in a drain. Taking me a while to make my mind up as I dont want to regret whatever decision I make.
 
Cheers,
Ryan

Will the car be parked outside whilst in your possession? If not then I think the extra drainage thing is a waste of time.  
 
Great work so far.  Keep it up.
 
Matt

Agreed, keep the drain hole stock, the water pooling is like factory evaporative air conditioning for our escorts and also negates the need for pollen filter.    
cheers

This is what I did for our RS2000 resto a few years ago.
The original round rusty baffle was removed and the sheet metal cut out to just short of the mounting points for the heater assembly. A removable replacement was made from 1mm stainless steel sheet. In this resto it was not necessary to remove the heater bubble because the rust was very minor which was treated with acid. As seen in the photos it is very easy to access the entire inside of the heater bubble. No welding was required.
 
 

Nice work Peter
 
JP

Matt75
Will the car be parked outside whilst in your possession? If not then I think the extra drainage thing is a waste of time.  
 
Great work so far.  Keep it up.
 
Matt

RS 2000
Agreed, keep the drain hole stock, the water pooling is like factory evaporative air conditioning for our escorts and also negates the need for pollen filter.    
cheers

Thanks guys, ended up deciding not to do a drain. It will be parked outside most likely, however if I seal it right it shouldnt rust.
 
I have flattened out the flange on the bubble a tad, so the water will come off. Also going to flatten the flange below it when I make that part.
 
Here's how its going:


Planning on glassing the holes below the section I cut out as it will be much easier.
 
Making the repair section fit:





Gaps arent as perfect as I would have liked however They are close enough for a good weld.
From inside:

 
Gotta make the section which isnt there, thats the next step. Wont tack in the top part yet as I plan to weld it to the firewall section then weld in the whole repair to the car.
 
Thanks for putting that up Peter, looks good! Putting the fan shroud in last is what I will do as well so I can seal the inside of the bubble properly.
 
Cheers, Ryan

Finally gotten back to the repair:
 
Made the lower section, welded that to the top section and tacked it into the car. I stupidly did this whilst I had no welding helmet thus the welds are not very accurate. I also blew through in spots (on the lowest setting on the mig) - an issue which I have now addressed with a piece of brass held behind the metal and the wire speed cranked.
 
Doesn't look too neat now but it certainly will when I finish the welding. There are cuts in the lower section, I made these to be able to bend the steel easier. The cuts will be all filled up with metal.
 
I spent a while making it symmetrical and I reckon its pretty good. Opinions on this statement are welcome!!!
 
You can see what I ended up doing with the heater bubble, it will not hold water on the outside now as I took away the lip. Also removed the lip directly below it.
 


 
Cheers

Nice neat looking job. Have you given any thought to using the factory drain pipe for Escorts with Kent engines? I got one but my engine is a Pinto so won't just push into the bubble drain hole - too tight a space. Haven't worked out if I can do a cut and shut on it yet. Len