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Heater Bubble Rust Repair

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79Escort
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2014/08/21 12:15:54 (permalink)
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Heater Bubble Rust Repair

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
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40 Replies Related Threads

    JVC063
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    Re: Heater Bubble Rust Repair 2014/08/21 15:23:59 (permalink)
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    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
    #2
    PeterM
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    Re: Heater Bubble Rust Repair 2014/08/21 19:11:41 (permalink)
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    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.
    #3

    Jaycees
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    Re: Heater Bubble Rust Repair 2014/08/21 22:53:47 (permalink)
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    post edited by Jaycees - 2014/08/21 23:04:42
    #4
    MK1_Oz
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    Re: Heater Bubble Rust Repair 2014/08/22 12:31:07 (permalink)
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    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
    #5
    79Escort
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    Re: Heater Bubble Rust Repair 2014/08/22 12:57:58 (permalink)
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    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
    #6
    Jaycees
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    Re: Heater Bubble Rust Repair 2014/08/22 15:15:08 (permalink)
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    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
     

     

     

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    #7
    Drewdog
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    Re: Heater Bubble Rust Repair 2014/08/22 18:22:44 (permalink)
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    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.

    GT Cortina Project "The Ugly Duckling"
    #8
    PeterM
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    Re: Heater Bubble Rust Repair 2014/08/23 01:13:23 (permalink)
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    "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.
    #9
    JVC063
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    Re: Heater Bubble Rust Repair 2014/08/23 07:14:06 (permalink)
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    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
    #10
    79Escort
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    Re: Heater Bubble Rust Repair 2014/08/24 18:28:31 (permalink)
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    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
    #11
    gg
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    Re: Heater Bubble Rust Repair 2014/08/31 22:40:06 (permalink)
    +2 (2)
    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.

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    GG.
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    79Escort
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    Re: Heater Bubble Rust Repair 2014/08/31 23:12:21 (permalink)
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    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
    #13
    Matt75
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    Re: Heater Bubble Rust Repair 2014/09/01 12:53:29 (permalink)
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    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

     
    My 4 door MK II Resto
    http://www.classic-ford.org/cfp/tm.aspx?m=37623

    RS Owners Club Victoria Committee Member - http://rsocvic.com/
     
     
    #14
    RS 2000
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    Re: Heater Bubble Rust Repair 2014/09/01 22:24:54 (permalink)
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    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
    #15
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