martymexico
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Re: Late 1980 yellow load lugger resto
2019/05/03 21:52:42
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The exhaust system came with headers that were in good condition, all I done was rough off the rust and have the system a squirt over with silver heat paint . Also I bought 2x sets of flanges and a flex pipe welded just behind the headers collector .  I bought a hotdog muffler to go at the back which is only to reduce crackle and there's not much back there to fit a good size backbox .  Got the head back and bolted it to the block   Things should move faster now
post edited by martymexico - 2019/05/03 22:13:44
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martymexico
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Re: Late 1980 yellow load lugger resto
2019/05/05 20:38:31
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Bit of a gap last month between posts as I decided to make the bonnet for the vans previous owner... The bonnet is mk2 escort. Here I'm sticking sides on from cardboard so it'll become a 3 piece mold and easier to make and crack/remove out the mold.  After the release agent dried I brushed on the blue gelcoat  5 layers of csm and some half tube to help strengthen the frame, waiting a week to dry thoroughly  I made the sides and back with the original return edge to replicated the original bonnet  Next was to prep the hinge mounts, cross brace and front slam which will use original latches etc, this pic is only gelcoat but the process is the same but less material layers was used. 
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martymexico
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Re: Late 1980 yellow load lugger resto
2019/05/05 21:13:03
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Once the mold was cured I carnuba waxed it 4 times to make sure it's fully covered and won't stick, this time the gelcoat is orange!  3x layers of 450 Csm was then applied and was let dry  Once the cross brace parts are trimmed and has nuts and studs installed I then lined the pieces up with measurements from the original bonnet and was then glued into place and lightly weighted down till it's fully cured   And that's the life of making mold and part, I forgot to take a finished pic, after so long working on it I don't really think to stop for pics, it ended up weighing 3.7kg..
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Paul Dunstan
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Re: Late 1980 yellow load lugger resto
2019/05/06 08:35:20
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You need to make RS bonnets Marty as theyโre HEAVY!!
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NQRS
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Re: Late 1980 yellow load lugger resto
2019/05/06 14:34:45
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I agree, that's why I had so much fun getting gas struts to work on my Bonnet!!
Cheers, Len
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blue74
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Re: Late 1980 yellow load lugger resto
2019/05/06 23:47:08
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You make it look so easy Marty, I like your build up pictures of the bonnet, looks like a nice piece of work.
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martymexico
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Re: Late 1980 yellow load lugger resto
2019/05/08 19:45:32
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Haha, that's why RSs are 100kg heavier than flat nose Escort due to the front end hang ons .
Paul, donate you bonnet and I'll fglass copy it. When I used to make them at Velo seats/Quickco they weighed about 4kg.. Much better than 17kg? of a real one !!
I can understand why Len went gas struts !!
Blue74 , its is easy to make although it's the preparation that takes all the time ๐
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Paul Dunstan
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Re: Late 1980 yellow load lugger resto
2019/05/08 23:43:12
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Maybe before it was painted Marty ๐
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Flighter
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Re: Late 1980 yellow load lugger resto
2019/05/09 06:42:57
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Hey Marty, plan on offering them for sale? I've always liked the idea of a lighter bonnet, but would only consider it if it used all the factory hardware, as I don't want bonnet pins.
WTB: Recaro seat - any condition considered
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martymexico
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Re: Late 1980 yellow load lugger resto
2019/05/11 14:00:42
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'Maybe before it was painted Marty ๐'. I understand Paul. I usually paint parts in 2pk before taking a mold as it doesn't react to the resins. Flighter, I make all my parts to replicate original fixings, ie hinges, locks etc... Unless someone just wants a skin only panel.. I'm in the process of updating a list of my parts /panels , the bonnet will be about $450 complete ..
post edited by martymexico - 2019/05/12 21:45:04
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Drewdog
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Re: Late 1980 yellow load lugger resto
2019/05/12 16:04:33
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Thanks for running us though the process Marty. That's some handy work.
GT Cortina Project "The Ugly Duckling"
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deano
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Re: Late 1980 yellow load lugger resto
2019/05/13 20:29:47
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Do you use polyester or epoxy Marty?
I'd be interested in knowing what you make.
Mk 2 Escort dash pad for example would be on my list.
Oh, the more I watch the yellow lugger progress, the more I could handle one quite easily.
(I'm picturing a flat front 2l mk2, silver metallic, blue Cobra stripes, 15"minilights, bubble arches, rally pack front spoiler and bumperettes)
More practical than the 4 door.
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martymexico
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Re: Late 1980 yellow load lugger resto
2019/05/19 19:47:34
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Hi Deano, I use polyester resin on my parts, it's cheaper and easiest to work with. Epoxy is for gear knobs and the like..
For mk2 dashtop there's a UK guy selling fglass copies that are 1st class, with all tabs and threads needed to install . Cost is about $250 from UK . I don't have a mold as yet for a mk2 dashtop ๐
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martymexico
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Re: Late 1980 yellow load lugger resto
2019/05/19 20:19:29
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Robbie
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Re: Late 1980 yellow load lugger resto
2019/05/20 10:45:11
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Nice work marty, ive been thinking of a retro radio myself.
I notice some sound deadening/insulation there, any hint on what you use? the only part of my floor insulated is the drivers side, thinking i might change that
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