martymexico
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Re: Rusted mk1 Escort coup resto
2021/10/15 21:25:41
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I gave the boot floor a bit of clean up, found the original colour of the car is silver, before it was blue, then another blue, then white, then on fire lol.  I'm giving this method a go, using tape to create the shape needed to copy, I'll make it bigger to allow for mistakes or other unseen dramas . The tape captures the shape perfectly  Now I have the map of the repair part it should be easier to duplicate  See how it goes this weekend
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escfalcap
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Re: Rusted mk1 Escort coup resto
2021/10/16 14:02:52
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What kind of tape is it Marty. Holding the pattern I can understand but the shape?
Got me intrigued.
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escfalcap
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Re: Rusted mk1 Escort coup resto
2021/10/16 18:38:46
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martymexico
From what I've read about annealed or zinc annealed is it's primary job is for car bodies and industrial fridges etc, it does bend without stressing, plus it's got that grey coating that holds back rust... I've had sheets on the weather for years on end and have only got rust on the tampered or scratched edges .. Mark, you should use this stuff , a full sheet costs about $80 from steel outlets ,I use 1.2mm as it's easier to weld being thicker..
Have a look at Kaka industrial, or Google up bead roller sales will bring up lots to choose from, getting a bunch of dies with it is something to look for as well , buying them separately will cost a packet, I bought the folding pr (1 is a skateboard wheel) . Next on your list is a shrinker stretcher machine!!
Marty, Was at steel merchant yesterday as I need some more sheet for the Escort tunnel (I will get build up one day, as I am taking heaps of pics this time) they have the zinc coated at 1.1mm. So will pick up a sheet. When I mentioned to him the problems with the straight black he said straight off that they store it with a film coating and lay all sheets perfectly over the top of each other and have a 'sacrificial' top sheet to protect the lot. See how it goes!
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martymexico
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Re: Rusted mk1 Escort coup resto
2021/10/16 19:28:28
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escfalcap
What kind of tape is it Marty. Holding the pattern I can understand but the shape?
Got me intrigued.
Just your regular making tape from supertheef , cheap n narsty stuff ! It kept the pattern ok but shape, I don't think I'll attempt it again but I did the Fitzee weld it in method, works well !
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martymexico
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Re: Rusted mk1 Escort coup resto
2021/10/16 19:46:24
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This is the piece welded in, I laid it over the top of the rusty piece and simply cut thru a few inches at a time and welded. This is the Fitzee fabrication method that actually works and is quite easy, just remember to allow a mm or two for thickness adjustment.   I put a return fold to add strength and give the other piece something to weld to .  Another piece I fixed was the very rear inner curve from the leaf spring hole to the back panel, kind of a cone shape quarter curve, easy done on the folder as it doesn't need to be exact I did the square to round technique.. This is the offending part..  This is the copy part 
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deano
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Re: Rusted mk1 Escort coup resto
2021/10/16 20:05:28
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good progress Marty.
2 arches got picked up yesterday via Fast (sometimes slow)Way.
Hopefully they get to you end of this week.
I wish I had a bead roller now..
And a shrinker..
Hardest thing with Fitzy sometimes is understanding his accent.
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martymexico
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Re: Rusted mk1 Escort coup resto
2021/10/16 21:35:23
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Thanks Deano on both accounts👍
Fastway/ or Anoraks as we call it , it'll get here by the weekend I hope..
I'm getting to the stage where the arches are needed to tie the other parts together, am going on uneducated guesswork right now hehe . The inner arches are pretty narsty , if I need to make a type of mini tub I will..
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martymexico
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Re: Rusted mk1 Escort coup resto
2021/10/17 18:58:20
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Cad work using a weetabix box to do the flat to replace the wheel well rusted n fiberglassed piece.  Here's the metal version with some bead roller action to give it some style and strength considering the battery will be living in this space  I made sure the indent is lower so if any water( usually heaps with Escorts) gets in it won't pool up at the seams  Next on the list is to make the lower side like the other side, then some welding will happen again.. I've still got to make the tramp bar bkts , ah later....
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martymexico
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Re: Rusted mk1 Escort coup resto
2021/10/18 19:50:26
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Can't thank Deano enough, the arches came this morning, before I had time to let the boss know there will be a parcel coming later in the week.. Also it took me half a hour to get into the parcel, very well packed and no damages that I know of hehe.. What was in the box was 1 rear arch and 1 front arch, I went straight to the front one and got thinking, it's about 1in wider than the back one with similar wheel well shape, check this out....  And this...  So then I swung the grinder at the old arch and trimmed the front one down..  And this...  I think I'll continue with the front arch cause I'm a bit crazy with this stuff , I'll graft the inner arch to match
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deano
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Re: Rusted mk1 Escort coup resto
2021/10/19 09:13:03
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wow, the arch looks bl**dy good Marty, like it was made for it! good skills right there. Glad it was of use, one mans trash as they say. Pressure is me know on to keep the van progressing so you can get the other 2... 
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escfalcap
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Re: Rusted mk1 Escort coup resto
2021/10/19 09:13:39
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Car wont know forward from reverse  Nice arch though, prominent without being big. Are you short a front arch now?
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martymexico
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Re: Rusted mk1 Escort coup resto
2021/10/19 22:07:12
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Deano, I'm amazed how quick they arrived and how cool the van front arch looks on the rear. I might've started a new thing, hope it catches on.. Mark, kind of at the moment, the front guards for this car will get Twink flares so the rears won't look out of place. I cleaned up around the rear arch this rvo and screwed the arch on so I know where it will sit. Finally bit the bullet and bought a Cleco kit, something I've thought of getting but done without, now the panels shouldn't creep during setup to final welding  And this was the dust...I had to evacuate for a few mins , time to beer it while the exhaust fans did their job..  Done a little welding as well, the flat panel into the spare wheel space, only welded the inner side near the chassis for now as I need to repair the rear side before anything gets joined up for good   I think I'll need to get the back panel cleaned up for a test fit to make sure I've got the repair panels lining up right..
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deano
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Re: Rusted mk1 Escort coup resto
2021/10/20 10:17:20
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cracking pace Marty.
I'm imagining once she's all painted up, people checking out the rear guards, but not being able to tell whats been done exactly, which is when you know you've nailed it.
Are those bigger tubs for the front, or just the photo angle?
Ha on the Clecos, you should have mentioned and I would have thrown them in the box too. I just haven't gelled with them in the end, I dunno if i'm using too large a drill clearance hole or what, just dont hold on as good as I expected. My go to now is just self drilling tek screws,, which help pull my panels in tight. Until they get taken on and off that many times the holes enlarge. I can now fill in the resulting screw hole ok with spots too, which helps.
Is that the engine that you are going to use, or are you going all Marty on us and fitting a Nissan Juke 1.0L 3cyl or equivalent? :)
Not fair also that you have already got some paint on.
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escfalcap
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Re: Rusted mk1 Escort coup resto
2021/10/20 10:45:00
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Deano, Didn't he tell you it was going to be the first Escort hybrid. That's what the HUGE battery tray is for 
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martymexico
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Re: Rusted mk1 Escort coup resto
2021/10/20 10:59:37
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Yeah I'm chucking in a couple of hrs in after work , keeps me motivated .. Those are original front tubs, I did think about the bigger ones but when they say their for 15" wheels, in racing/rallying that also makes for a taller tyre. I usually rake the fronts forward for better cornering , Ackerman effect, more angle etc. I didn't know I needed or wanted Clecos till the arch arrived, prolly watching too many resto shows, if you don't want your pins I'll buy them, send with the next arches🙂. That engine in back is the 2.3 duratec destined for the ute with the 2.5 duratec converting the internals. Next to that is a zetec and next to that a pinto !! It might get the pinto as a starting point, with bike carbs 🤔
post edited by martymexico - 2021/10/20 11:12:51
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