Bother !!
If I wasn't trapped doing the rally pack I would very consider this, he's already blacked it out as Sundowner already..

Wow that van is already pending! Not even up for a day...

I swung past the panel shop today to have a look at the roof and a closer look at the quarter panel after they sanded some more back, I am even more convinced replacement is the way to go, it's hard to capture on photos just how bad it is but here are some more.
 
You can see where there is a panel join or crease or something in this shot, it's hard to tell exactly what it is. The panel here is super wavy underneath that seam.  

 
Here is the part under the window, the bog there is about 2 to 3mm thick in places, which is where the paint was starting to bubble up a little. The closer you get to the door the straighter it gets / less bog.

 
Some good news though the roof looks great! I took some snaps of how it sits and where they're just making some final adjustments to get it to fit really nice.
 
See where it sits up a little in this shot, thats the last bit of adjustment that it needs then it will get spotted / seam sealered in.

 
The other side.
 

 
The front sits perfectly on both sides.
 

 
The parcel shelf is all done now too, the new panels they made up and put in come up a treat.
 
 

bugger about the van, that was a good starting point for someone.
 
I see about the quarter panel, yep sometimes the camera can make things look better or worse than reality.
Roof skin is definately a winner, they are cracking along nicely.
 
 

I brought this to my attention, the roof skin at the back is squared off where the lines meet , I've got a pic of my Rally Pack back roof corner to compare, you'll know what I mean right away .
Maybe show it to the guys if they haven't noticed..


Anyways the progress is coming along well.
I'm getting some concreting done in a few weeks hopefully and had to move my 2nd ever owned car from 1996 it was my daily for about 10yrs then parked it up, it has all the mods done inc 2.1 pinno and 5sp and LSD etc etc

Sheepskin covers over Cordia GSR turbo seats lol

I'll resurrect it one day ...

I see what you mean, its too sharp at the "join" I'll get them to shape it a bit there - great pick up Marty!

Not Escort related but small Ford related, had a mate ask for some help fixing up a RS1800 inlet manifold for a project he has going on. It was a bit banged up here and there so smoothed back the worst of it and ground off the casting ridges to smooth it out the runners and make it look a little nicer.


 
Cleaned up the "EFI" letters with 1200 wet and dry, masked it all up then hit it with etch primer then high temp wrinkle paint to hide the imperfections. I think it's come up great, needs a little touching up with a tiny brush around the edges of the EFI letters but it'll look great in the car.


 
He needs to get the sandwich plate for the injectors and the fuel rail cleaned up with some glass bead blasting and it'll be ready to go back in. I cleaned up the throttle body for him with a brass wheel, came up pretty good too. 

Funny..
I have I've of those intakes all complete, had it since the zetec came along back in 92 -93 mine came with the Burton stage 2 cyl head and cams etc . It actually came from Spencer Ashley's dad's (Ashley exhausts) wrecked Festa rs1800 Rally car.
Along with the injector block there's a ally sandwich plate with channels to read the manifold vacuum.
A bigger throttle body from Focus or Mazda Duratec will wake the motor up a little 😉

What you did there looks good

Yeah they're a pretty trick little manifold, I like the runner length for low down torque and the throttle body isn't too bad - I don't know what its off but I don't think its the standard one as it has a 55mm plate. He was thinking of putting on a focus one but that would mean cutting up the manifold from what I can see.

Do you know what port is for the booster? The one at the top or the one at the side from those channels?

From the image below (if works) I think the brake vac line is the at top of the letter I of EFI . Unsure what all others do , just wing it and see how it goes.
I was going to use my intake for turbo on a previous build but it never eventuated
https://images.app.goo.gl/8jCsNtUEtVNs2ivh6

Yeah that looks about right I think, the other one must be for some sort of emissions/EGR, can always block it off or get those channels welded up.
 
It's got two other ports on the back for more vacuum stuff so easy to put a MAP sensor on  which is what he is doing.