Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/03/11 19:54:55
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OK, time to tackle to "A" pillar rust. Decided the best way is to remove the gutter and replace the rusty sections and then re-attach the gutter. Had previously had a go at plug welding the holes from the front but proved unsatisfactory.  More to follow as I progress - this is the removed gutter section from the "A" pillar door opening. Clearly shows the major rusty sections.
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PaDDy555
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/11/14 18:07:12
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quote: Originally posted by Paul Dunstan
OK, another mediocre update [:I]
Purchased another set of rims to get some decent outers. Found it will be cheaper to do it this way instead of paying to get the others refurbished. Anyway, I now have a set of 15x7 and 15x7.5 which should be ideal considering the offest of my centres will currently have 24P on the front and 18P on the rear.
I now have an array of inners and outers plus 7 Porsche centres which I have started listing on Ebay!

what brand/type of rims are these??
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jds
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/11/14 19:05:19
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quote: Originally posted by PaDDy555
what brand/type of rims are these??
Simmons V4.
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jds
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/11/14 19:09:47
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quote: Originally posted by Paul Dunstan
OK, rotors now in place and all looks good

These struts look interesting, can you tell us more about 'em please?
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/11/14 20:05:13
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Hi JDS. Thanks - yes they're Simmons V4 which I've altered to my preferred width (15x7 front, 15x7.5 rear) after obtaining, selling and swapping many rim sections etc  Struts are from a car I obtained and sold on. I think they're standard Mk2 2.0L struts with the lower spring seat removed. A threaded section of water pipe was then welded onto the tube and a threaded "nipple" added to the spring seat. This has produced a rather crude adjustable spring platform. It also has a locking nut below the spring seat. It aint pretty but I guess it does it's job. Also has Bilstein inserts. Brakes are explained earlier in the thread.
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/11/23 19:01:51
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OK, another step forward as a parcel arrived today    Now I have the last piece of the puzzle I can proceed with the engine mounts confident everything will fit without fouling [:x)]
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2009/06/12 23:14:14
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Trying to get stuck into the remaining rust repair to ensure it's ready for paint when the time comes  I needed to remove the under side section of the "A" pillar as there were rust holes all the way down which required the drip channel to be removed in the previous photos. Section removed - difficult to see but holes are visible in the centre-line of the panel.  Where the rusty section was removed.  This then required a replacement section to be cut to size and grafted in.  Unfortunately time got away and I was unable to begin welding - stay tuned  I may be best to mount the door to ensure correct alignmant etc.
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ash
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2010/11/01 15:26:24
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Martymexico, you recommended in this thread that Paul look at Telstar/626 handbrake cables for the R31 calipers.
Did you manage to get this working on your car?
If so, could you post some close up pics.
Cheers Ash
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2010/11/01 16:20:56
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Hi Ash
Posted similar response in your other post. You need all the R31 hardware to make it simpler.
Look here for a Torana conversion (same principles)
http://www.gmh-Torana.com.au/forums/index.php?showtopic=30223
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2010/02/21 22:44:25
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OK - some of my profile cutting has returned (along with the remaining rear brake kits for those waiting - terribly sorry) so I thought I'd see how the new cross member mounts will look. I still need to prepare some angle (with mounting holes) to be welded into the right angle relief as this will resemble the original mounting arrangement. I will then completely box the upright and will mimick the WCXM style mount. I have prviously had the the engine mount plates cut so once this is finished I can fit the cross member and finalise the engine position and finish the mounts.  
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2010/07/03 20:54:28
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Had a bit of time today. Removed the other original engine mount from the Xmember to allow the fit up of my new mounts below. I will box them with the sections shown infront and obviously the engine side of the mounts are rotated 180 degrees to hold the bush tubes in place for the images. I will use 90 degree angle to replicate the original mounting flanges to the chassis rails.   Also picked up my sections to fabricate my bias pedal box   I honestly believe I have an illness as I'm obsessed with profile cutting [:x)] For the price it's a no brainer compared to cutting by hand!
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Dave
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2010/10/03 09:00:42
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paul g'day Its all looking good. Back to the rear disk conversion for a tick and a couple of questions, just for ease of set up,I was going to go for the complete r31 set up caliper factory mounts and rotors if I can find them( and machine the rotors to suit the escort PCD),but I need to know how far it pushes the wheels out? ( I have only about 10mm clearance under my rear gaurds),and Im assuming you fitted longer wheel studs?.
Cheers Dave
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Paul Dunstan
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2010/10/03 18:42:03
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Hi Dave Yes, it will add a little extra to track width - the diff between the rotor hat thickness and the drum brake (I doubt it's >5mm though). I also looked at the original R31 mounting plates but I found they were not ideal - I found my adapters easier as I could design them to fit correctly. I will be using longer studs. Adapters V2
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Dave
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2010/10/03 19:01:36
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martymexico
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RE: Paul's Mk2 RS2000 project - Now going ZETEC!
2010/11/03 09:31:58
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Hey Paul nice work on the x/member, just make sure you have plenty of clearance for the steering knuckle on the driver side. Keep up the good work
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