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Hot!Another Escort Van Project: 77 Mk2

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martymexico
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Re: Another Escort Van Project: 77 Mk2 2022/09/19 19:33:11 (permalink)
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Nice going deano, a shed fire is something we all dred , even small ones like yours, makes ya really think what could've happen. Glad you controlled it without panicking..
A friend of mine had his shed melt with 2x mk1 Escort coupes cooking away with nothing he could do but watch and cry. Culprit was a Makita charger so when your done, flick the switch off regardless if it's not charged.
All of my chemical tins like paint, thinners, resin etc etc are kept in a metal cabinet in another closed off part of the shed.
Those side plates look fine from here 👍, you should be happy. As with the heater bubble panel, it's up to you. If you glue it on, use some gasket maker type of silicone, good bonding but easily peeled off when needed. If you weld it on, remember to use sika joint sealer on the inside under the dash to stop any pin holes causing leaks/rust. Also drip paint from the top edges inside the bubble cavity to also seal any bare metal as best you can. I drip in thick paint a few times to make sure it's proper coated. Done this to a car 20yrs ago and it's still like new.
deano
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Re: Another Escort Van Project: 77 Mk2 2022/09/20 08:59:14 (permalink)
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Thats a sad story Marty. Makes you wonder how so many people felt with all of our bushfires. Losing a garage would be bad enough, but when people lost absolutely everything everything, it would be devastating.
It's nice to be able to switch off the shed power, and know there's nothing inadvertently left on.
 
Ok with the heater bubble, I think we'll go welded, with plenty of sealer and internal coats as suggested. That sounds like the way to go. I'm out of weld through primer, so will have to get some on the weekend.
Its nice to get some small jobs out of the way.
 
Oh, and for those that way inclined, go Cats.
Everything is suddenly becoming blue and white down here for some reason.
 
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Re: Another Escort Van Project: 77 Mk2 2022/09/29 12:44:28 (permalink)
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got some painting done last night.
Not too shabby in epoxy primer if you squint, cant wait until some high build goes on.
Next job will be to undercoat the front inner wheel wheels so the guards can be put back on.
 

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martymexico
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Re: Another Escort Van Project: 77 Mk2 2022/09/29 13:27:16 (permalink)
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Progress on, I can see a paint run hehe, not really lol...
I've noticed when I get a panel in primer I can relax a little and know the final painting isn't to far away. Have you tested the red I sent you yet ?
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Re: Another Escort Van Project: 77 Mk2 2022/09/30 13:20:01 (permalink)
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no not yet Marty.
I have a small group of the suspension parts that with be Marty Red, but I want to pull the front springs off and the ARB and do them as well. I have an unused touch up gun that has been gathering dust to try out.
 
The next job listed will be to refit the heater bubble, as well as getting some paint on under the front arches so they can go on.
 
Next brainstrust question: the fuel filler update.
I have a new filler cap assembly as below hiding around somewhere and I'm pretty sure the existing bodywork flange it recesses into will be too small. What are the chances of making a round timber plug and form to press a piece of steel down to form the recess ? then cut the inner hole out afterwards. Then cut the existing filler area out and fitzy the new panel insert in.
 
I know some of you guys used this timber die method in other threads to replicate  floor ribs, but wasn't sure if it would work on what might be a bigger scale?.
I'm guessing it may be hard to clamp the panel steel tight enough to stop it warping, and youd need afair amount of pressure to create the recess?
Another method might be to use the shrinker/stretcher? or just cut the hole out and manually form the shape needed over a large pipe offcut?


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martymexico
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Re: Another Escort Van Project: 77 Mk2 2022/09/30 14:53:38 (permalink)
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Ahhh, this will be fun..
Easiest way I can suggest is use a piece of sheet steel and mark out the hole but maybe 5mm larger for errors , this circle will be where you fold back for the countersink, using the wood plank with hole in it.. The plate needs to be screwed down goodly and maybe have about 10mm lip of which some will get cut back to your desired cap height, once that donut is done cut another circle to weld it to the lip. weld the back as it'll be easier to clean up later, then cut your filler cap hole and screw holes. If it distorts a little, use it to your advantage with the curve of the panel. What your doing is making a paint tin lid in a way 😎
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Re: Another Escort Van Project: 77 Mk2 2022/10/06 19:27:37 (permalink)
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Hi Guys been offline for a while for various reasons.
Health is good. So looking forward to getting back on with the track car and the boat.
 
Just trying to catch up on whats been going on.
Not that you want to buy one just for this one job. Cause you would probably never use it again.
But a dimple die would work. I'm not sure what increment diameters they are available in?
Maybe borrow/hire one?
Then you can weld your flat plate with pre drilled filler hole and mounting screw holes to the dimpled edge just as Marty has said.
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Re: Another Escort Van Project: 77 Mk2 2022/10/07 10:59:26 (permalink)
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Good to see you back Mark.
Definitely boat weather soon.
I hope mine is where I left it, given the wind fronts and rain we have had.
 
Anyhow, I will give the die a crack, and Marty's idea of the flange then welding the flat backing on. When I deleted the roof vent, I used the air compressor for the first time to cool down between tacks, and ended up getting more warping than every before.
 
Bathurst this weekend, so should be an excuse for everyone to get some shed time in. :)
 
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Re: Another Escort Van Project: 77 Mk2 2022/10/09 18:47:36 (permalink)
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Hey Deano, The highlight of my weekend was taken away. No top 10 shootout  (The rain we have been having here is unbelievable.)
Funny, but I can't really get into the main race anymore. Maybe its the commentary or the sterile nes (new word)
of the cars. Its like formula racing now, just pour in the dollars. Sure the skill of the driving is awesome and Bathurst will forever be the pinnacle of road circuits in Australia. Perhaps I'm just becoming a boring old fart
 
Yeh I'm not too sure with the warping, I've got a fabricator friend and so tig when I've wanted that sort of patch up. Done a couple of blanking jobs of the the side fillers on the MK2 Escorts with mig and not a problem. Maybe its a smaller area and its fairly solid in the pressing there? I know when I fabricate tunnels/pans it does warp slightly but obviously a slight warp there is not a problem.
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Re: Another Escort Van Project: 77 Mk2 2022/10/10 09:13:13 (permalink)
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Your right Mark, v8 racing is a bore, the commentary is a big turn off as is the 1 make race cars with different skin to loosely reasonable a production car. I don't understand how they are called supercars tho, that amazes me lol
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Re: Another Escort Van Project: 77 Mk2 2022/10/10 13:04:49 (permalink)
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Well Bathurst wash a wash out!.
Yep, time Skaify hangs up the mike too I think, so many times he was just wrong and Neil Crompton had to correct him. Plus just yelling does not make commentary exciting. Good to see a Capri come 3rd in one of the support races.
Not the same without Lowndes, The Enforcer etc going at it back in their old cars. Plus the Subway ads gave me the poo's as well.
 
Anyhow, a bit of time in the garage:
still needs more tidying, but a bit of paint on the floor

 
 and etch prime of a few bits:

 
made up a new headlight closing panel on the passenger side
 
 

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deano
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Re: Another Escort Van Project: 77 Mk2 2022/10/10 13:18:55 (permalink)
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and patched a section in the drivers footwell which will need redoing again (not showing the pics :)) , the old floor was too thin in spots to weld nice and it ended up not satisfactory. One step forward and 3 back. I agree Mark, it is a pity we are spread out so far, sometimes it would be nice to have another pair of eyes to critique/guide. 
 
On that, the next challenge: lining up the front lower guard to front apron.
Looks like when I dressed the wheel arch over on the bench, it ended up puckering the lower front edge up, as below.
 
 In the pic, there's no clamps holding the front returns together, so there is some scope for aligning, but the front apron return  doesnt really want to curve up as far as needed. Without having much to go by, it's a bit hard to tell where the correct line is: should the guard edge go down, the apron up, or maybe a bit of both? I suppose a bit of both in the end, so long as each side ends up symmetrical from the front...?
How do you even get the welder in to tack it together? There is b*gger all space. May even be worth drilling and fixing together with metal threads along this lip?
Fun and frustrating in equal measures.

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Re: Another Escort Van Project: 77 Mk2 2022/10/11 09:24:20 (permalink)
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You did a top job on the wing closing panel, you could've used the shrinker stretcher on the return edge if wanted but it looks a tight corner.
Front guard needs to come down by the looks, there is some flexing to do to get the front panel right. As for welding, I notch the lip and weld it or if both panels are not accessible I just blast the seams together then finish of with seam sealer . Alternative idea is weld tabs and bolt the guard on 🤔
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Re: Another Escort Van Project: 77 Mk2 2022/10/11 12:55:24 (permalink)
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I did try the shrinker Marty (for the first time :(), but it did not look like it was going to even touch it, did not want to grip the panel much. I frigged with it for a few minutes then went old school and bashed things until it started to look remotely similar.
 
The inner guard does have flanges, so I might end up blasting the edge as suggested, and bolting closer to the inner seam if it still feels like it needs keeping closed.
I found a new 1 lt tin of 1k  PPG spray filler bought for the 4 door this morning, so that was a bonus.
Any updates from you Marty?
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Re: Another Escort Van Project: 77 Mk2 2022/10/12 09:54:44 (permalink)
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Haha, yeah I found out the handle doesn't do it , that's why I rigged up the foot operated method, next I'll be using an air cylinder with regulator to further easy up the device.
At least you got there and made a decent copy panel..

Nah nothing on my coup for months, a mates van has been taking up most of my weekend time when I'm the shed, and the mk1 Focus .
I did buy a pair of falcon GT teardrop mirrors from that guy in Sydney, $80pr !!
Last weekend I was on hols down at Keith, nearly 300k from adel, almost on your doorstep mate 😆
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