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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 2025/01/13 11:10:19 (permalink)
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Zorst looks good, was it just MIG'd up with regular wire ? I only done mine with Tig cause I need to learn it more, I don't like having tools I can't drive. I'll have another go at making an alloy cheese wedge water bottle again .
deano
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Re: Another Escort Van Project: 77 Mk2 2025/01/13 13:07:27 (permalink)
+1 (1)
hey, a side exhaust is cheating!.
No diff hump to worry about, plus you ran it down the rhs and not worry about the tailshaft crossover either!!
 
Alloy cheese wedge: Marty have you seen our YT upholstry mate recently?
I was refreshing how to redo the front seats, and found him replacing seat bolster foam.
He just used blocks of high density foam, trimmed roughly with the std elect carving knife as normal, but then shaped down into the right contours using the old style chrome  wedge cheese grater.
Watching it, the foam comes off more in chunks, and gives you way less mess and dust than sanding with a DA orbital.
 
I bought a can of ths Car builders Spray Adhesive to try on the headliner. 
It seems to have had good reviews.
 

martymexico
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Re: Another Escort Van Project: 77 Mk2 2025/01/13 13:40:07 (permalink)
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Yeah I seen that neat trick, don't think the misso world appreciate sponge in the grated cheese! Might buy a specific one for foam adjustments.

Spray adhesive for hood lining on those side plates your planning on.
Roof lining should be brushed on where it meets the window and door returns etc, just less mess, spray for bigger areas that overspray won't be a problem, you know what I mean .
I've usually used the selleys Kwik grip to brush on, lasts for donkeys..
post edited by martymexico - 2025/01/17 09:34:13

MarkA
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Re: Another Escort Van Project: 77 Mk2 2025/01/13 14:38:54 (permalink)
+1 (1)
Yep Deano. With the Cossie its all fuel and electrical up the passengers side and exhaust under the driver.
Well one look at the diff hump and I knew I would have been in for a world of pain. The RS is pretty quiet, so fingers crossed I won't need to get out the steel wool!
 
My upholstery guy has a mini spray can he attaches to his airline and does all the tight areas. Obviously he's doing it all the time so he doesn't even clean out the gun.
Anything Car Builders is good so I reckon you'll be right. The underbody pics of my exhaust, you can see their stick on heat shield, joins are done with their aluminium tape. Time will tell once it gets some heat onto it etc.
 
Marty just tell her its a new style of aerated cheese. Better for your waste line
deano
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Re: Another Escort Van Project: 77 Mk2 2025/01/30 13:06:09 (permalink)
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still here laboring away. 
This years goal might be to finish something before moving onto the next job.
So with that in mind, here's the exhaust, well the diff hump bit, the rest is fitted on the car..
I'm 2 welds away from completing my first ever exhaust, tonight fingers crossed (MArried is back on too).
 
I was suprised how carried away you can get making it fit every which way, rather than just be a functional pipe to vent gases out. See how many bends and welds in this bit alone. It gets close to the van petrol tank at the bellow.
 

The temptation was to linish the welds back too far, in the sake of appearance maybe over strength, who knows.
One trick I did learn though, was using a hose clamp to work out the cut angles when you dont have a cutting gauge:

I'd seen 'Hand made by Jeff" YT use cable ties to do the same thing, which I tried but they were still flexible enough to give you an 'out of perpendicular" cut guide. This was an issue when you're cutting the 90's down to whatever angle needed, and go to butt it to the next round tube, a bit like buggering a cornice.
Using the hoseclamp solved this and was easier to cut if using the angle grinder over the drop saw.
 
It was also  good suggestions of Marty's to just buy  a stack of 90 degree bends initially, which you can obviously cut down to whatever required.I used 51/2 out of  the 6 bends. It probably would make fitting easier with an extra vclamp in there too, should have bought an extra.
I was happy with the diff hump work of art, I think it will make the hotdog come out in the right spot, and at the right angle but we'll see.
 
 
 
 

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martymexico
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Re: Another Escort Van Project: 77 Mk2 2025/01/30 15:48:02 (permalink)
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That'll work, looks good to me. Pity it won't be seen unless on a hoist or ramps. Hose clamp trick is a winner, nooice!
I made your splash guards today while making the bumper for a Mercedes and tomorrow I'm planning to get your bumpers modified as we discussed.
Next week here is going to be a melter , summer finally arrived

deano
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Re: Another Escort Van Project: 77 Mk2 2025/01/30 16:59:04 (permalink)
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I downloaded Gimp software also, but havent got the cad laptop here..
At a minimum, it might be another handy tool to convert file formats around easier.
MarkA
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Re: Another Escort Van Project: 77 Mk2 2025/01/30 19:33:29 (permalink)
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Looks pretty good Deano. As long as it holds together ok you'll be happy.
One thing which helped me was getting my exhaust guy to open up the ends (on some off cuts of various lengths) so I could sleeve the joins rather than but. If one end is opened fairly liberally then the next piece slides in and has enough wiggle room to introduce some angle and then just tack, check, adjust and weld it up.
PartTimeMK2
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Re: Another Escort Van Project: 77 Mk2 2025/01/31 08:54:43 (permalink)
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Awesome work mate, if the angles aren't quite right you can always heat it up and tweak it on the car, just need a big pole to stick down the exhaust .
deano
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Re: Another Escort Van Project: 77 Mk2 2025/01/31 14:48:32 (permalink)
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ha, thanks guys. Its done now and another job ticked off.
Thats the good part.
The not so good part was I was just finishing off, and noticed one of the hanger brackets could have done with an extra dollop of weld.
It was just a small amount..
So I thought i'd be ok without the welding mask on, do it Vietnamese Welding syle, close your eyes.
I welded upside down fine, but a hot welding splatter shot down my left ear ole.
I heard it fizzle as it went.
I suppose thats a welding right of passage somehow, and a lesson to always wear ppe.
 
martymexico
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Re: Another Escort Van Project: 77 Mk2 2025/02/02 10:14:18 (permalink)
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I was doing the help tutorial on Gimp and the interwebs was so slow , found out we'd hit the max allowed for the month, Damit ! Another 2 days wait, argh !!
deano
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Re: Another Escort Van Project: 77 Mk2 2025/02/02 17:20:10 (permalink)
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throttling eh?
That will teach you for trying to learn the proper way.
 
Pretty hot today Bruce, even in the shed.
martymexico
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Re: Another Escort Van Project: 77 Mk2 2025/02/02 20:27:16 (permalink)
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I'm trying to help hehe. Think I'll just get the gasket out again and scan it then work from there on fusion 361..
So glad I got the fglass jobs did last week, no end of heat coming this week. I'll get your stuff wrapped and ready soon..
No gb for another day...Haven't watched regular TV f for years, now I know why, it's rubbish !!

Yeah we had a real warm weekend, and week coming apparently..
My cousin who lives at the marina, some poor guys yacht about 200mtr away caught on fire.. Oh thanks for sending all your forest smoke and lipo battery smoke our way too lol . SAs air quality reached 160 from a regular 40, what ever that means.
deano
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Re: Another Escort Van Project: 77 Mk2 2025/02/03 12:48:30 (permalink)
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the best part about 38+ degrees and having the Cadel Evans bike race on in Geelong meant we were trapped:too hot to take the dog to the beach, plus the top of our street was cordoned off anyhow for the race.
Which meant more garage time, interrupted only when the choppers flew overhead, so we'd wander up the street just intime to watch the team cars, police motorbikes and everyone fang past at breakneck speed.
 
Some painting satin black:


a bunch of headlight buckets and headlights
 
 
then back on the wheels for the first time that I know of, with a Pinto fitted

 I fitted one of each style of headlight, to mull over. Plus it all has to come out again anyway.
The skinny rosyles are growing on me.
I have some Performance Superlights with 14x6' tyres on the Capri to use come RWC time, or maybe it might be worth getting something cheap to use on these rims.
Next job is to dig the wiring loom out again, and make a proper effort this time.
 

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deano
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Re: Another Escort Van Project: 77 Mk2 2025/02/03 13:08:37 (permalink)
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speaking of wiring, I saw that Martys SA neighbour TAff is making these updated fuse blocks with 8 circuits that take the modern euro style fuses.
Im not sure of the pricing, but they apparently go in the same location, and can be for either Mk1 or Mk2.
I had bought just a generic std fuse block that runs the wiring out each side, but what I think Taff has done is to 3D print a spacer that raises the block and covers up one side for underneath entry: ?
 

 
 

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