I succumbed to peer pressure and messed around a bit more. Mounted the tray in a similar spot to Marks old RS and welded up the holes I made to mount it in the first spot.


 
I have treated this tray pretty poorly but it was only 20 bucks from Jaycar so grabbing a "final" one isn't going to break the bank.
 


Just need to grab another couple of L brackets tomorrow to finish it off.

New heater core arrived today so I tested it then chucked the box together.
 


The core is good quality, lighter than the old one and holds pressure. Fitment is good too. Another job done, ticked off and its up on the shelf now waiting for re-assembly. Putting back together wasn't too hard, I found it was easiest to assemble the side with the blend door controls, flaps, heater core, fan and resistor on the bench then slide the other cover over, that way I just needed to situate the flaps properly so it all slid together nicely.
 
Also dont forget to put weather stripping around the core to get a good seal on the inside of the box. The stuff I had on hand - 5mm thick - that i used for the edges of the flaps was fine.




 

Looks good Mark. That heater box looks especially good.
I agree with Marty though. Stainless or plastic for the battery tray. If you persevere with steel then be wary of what sort of battery you sit in it.

Heater box looks good enough to be coffee table art !
I think I should get on the bandwagon and start working on the heater box for my mk1 Escort , mine is a metal frame so it'll get a 2pk in silver just so it will be easier to hook up cords n wires etc, might go electric instead of water core.

Ill be interested to see how that shakes out, I was considering a electric heater at one point but decided against it. Will you get one that fits the original box with some creative assembly?

Guys, One thing I have noticed with my builds is their tending to get higher engine temps. Its quite amazing in the RS now its all finished and going, when I turn the heater box to heat and turn on the fan, the engine temp drops by a few degrees. That little core with basically a thermo fan (very efficient with complete shrouding) stuck on it has a very quantifiable effect.
I think this is just something to keep in mind.

MarkA, Yes it's like having a remote oil cooler but for water. Tho an ally rad will fix the coolant warm thing .

Part time Mark, the last one I did I used a caravan electric heater box but removed all but fuses and switches to be fabbed into the heater box. I made standoffs to locate the electric core and used non flammable high density foam to seal the flap doors etc, just so it's safe and piece of mind . It takes about 40sec to warm up independent of engine running ..

Ill be going the alloy radiator and thermo fan route more than likely. I have a lovely hole in my thermo housing that is now surplus to requirements that could house a sensor nicely, just need to get the right thread. 

I've been messing around in the boot still and I completely underestimated how much of a stuff around this would be to do. Thank god for CAD - cardboard aided design .
 
The spare wheel is under there, it all fits and there is room for the jack too. Now i just need to use these parts as a template for the final one as there were mistakes made, the top panel is about 5mm short where it meets the back of the boot lip - lucky the MDF is cheap, the other side SHOULD be a breeze as its just the same parts reversed.

I actually used a stack of magnets to help hold in the top panel, you can see them in this photo at the top there, on the final one ill build up that edge with a few strips of MDF glued to the panel with a strip of magnets under the upholstery. That 10mm drop down is needed to let the boot lid clear the panel correctly.  

I've designed it so the spare wheel will be accessed by undoing six screws and the panel will separate and pop out. I'll also use black countersunk M6 screws for every bolt you can currently see. 


 
Once the final pieces are made up ill bog up this join, then i'll grab some boot upholstery from car builders and make it look all pretty .
 

 
Even managed to make it level.
 

 
 

 
ill need to shave a mm or so at the bottom to allow for the carpet to wrap under. I'm happy how its turned out, I still need to fab up the back panel but that will be a piece of piss compared to that headache.
 

Halfway done on the other side, went a lot quicker with the other as a template, some minor adjustments were needed but she's an old girl that's had some war wounds .
 
That's enough for today, time to kick back. I'm headed down to Geelong tomorrow to pick up some quarter panel glass, my drivers one is damaged and this one is apparently pretty good. He also has an ignition switch that he said was seized, I may be able to salvage the wiring off it though for mine.
 

Looking good.
Subwoofer box next!
 
I'm not sure whats happening tomorrow yet, but if you are coming to Gtown, feel free to swing past if you want a look at the van.
Just bring bring your tools Mark..:)