mallard green S2 resto (24/7/11, fuel filler relocation complete)

[BrianEscCos]

fantastic work there, well done so far

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[AndyKam]

Any updates?

[Rs Adz]

as said still looking brill any up dates

[RSandy]

not a lot happened with it lately, car kind of been buried by kitchen units and the like due to house modifications lol

still awaiting my rear hubs to have the studs pressed in, my dads mate took em to work, and on the final stud, the hub cracked, so trying to find a single outer hub section to try again with, hassle!

and i lost some stupid little spring thing that attaches where the brake transfer bar meets the servo, so need to get 1 of them too

gonna cheer myself up and have the tyres fitted on my wheels when my mates tyre fitting machien turns up at his new unit, then fit em on the front n see how nice/terrible they end up lookin lol

[Glenn.]

Nice work nice to someone doing all the work themselves.

[B16 Will]

Thaught i recognised rice boy (pal of my pal jason, RJ Tuning)
Just read the thread from page 1, looks an expencive and down rite barmy build yet worth all of the blood, sweat and tears!! Nice one

[RSandy]

suppose i better update this lol

things have been at a bit of a standstill due to redundancy, the run up to xmas and new year, and not to mention problems with parts gettin damaged

1st up, my troublesome rear hub. as with the fronts i wanted to convert to stud and nut set up, and to get the studs in correctly, i sent them off with my dads mate to have them drilled out and pressed in nice and snug....

.....only i think they must have forgotten to drill the threads out of 1, cos this happened:





they thought it would be ok welded, but i thought otherwise, as once a casting is cracked, like that, its better to just bin it

so i hunted for another replacement, and after buying an incorrect 1 from a van, and being offered 1s at extortionate prices, i found 1, had the studs pressed in, and happy days

here they are being painted up ready for new bearings and bein fitted on



and heres some other misc parts also gettin same treatment, as im now sadly full on bufty spec!!!



most the bits im cleaning up and painting up are for my brake system, and i decided that the brake fluid reservoir didnt cut it, found out they obselete so a new 1 wasnt an option, so a tub of bleach and a brick method was used



and heres all the parts all clean, shiny, and ready to fit:











also forgot i bought these at 1 of the shows, after matt lewis did me a great deal on them, so would have been rude not to:



as soon as the brake bits and steering rack are fitted back up, and my brake lines are made up, its engine build and fit time, so the big changes are on their way

[bonus_boy]

so this is the rs that needed a rear hub..

loving the colour choice, and work thats gone into it..

[xrmalin]

ausome build mate cant wait for you to start getting some bits into the bay

[RSandy]

Originally Posted by bonus_boy

so this is the rs that needed a rear hub..

loving the colour choice, and work thats gone into it..

cheers dude

yeah, did go over and see your mate, but the 1s they had were the small base spec hubs, where the hub section is cast into the drum shell, so were no good sadly

luckily philly willy stopped bein gay for 5 minutes and found sum1 with 1, so all sorted lol

[bonus_boy]

ohh dear, sorry about that matey..

glad you sorted it now though..

[andy escos]

thats a lot of work you have done their mate looks like it will be mint when finished top work m8 keep the updates coming

[alanfordtw-15]

amazing build, your atention to detail and paitents are unreal. good to see its its own car and not another s2 bolt on job.
keep it up!

[RSandy]

bit of an update, some good news, some bad news....

start off with quick test fit of my cooler and the twin fans to make sure they clear the new bumper..



amazingly clears without even having to chop out a load of the bumper, which is nice

then went on to finish prepping the bumper for high build. bumper has had a hard life so lot of places have been taken right back down to bare plastic to get the dings gone:





thats all smooth now, so theres some of the good news i was talkin about.

now for some of the bad ....

when trying to fit my front anti-roll bar and engine cradle, i started having issues with bolts not lining up very well, infact some miles out. after lots of faffing, lots of swearing, and generally throwing a wobbler, i called for help

turns out that even though the new crossmember was fitted up the the original marks, and was fitted up with the bracket loosely, something has gone wrong, and its just not sitting correctly. infact when the brackets are offered up, a lot of the issue is the pattern part panel is way out, like holes 10mm off kind of wrong, and nuts that arent the right size for genuine ford bolts, so no amount of bashing is going to fix it. talk of opening out holes quickly led on to issues with geometry..... bad times

so, taking a deep breath, the grinder and welder are coming out again for another blast, because i amazingly found this today:





brand new genuine ford front crossmember, only cost me 30quid, which was same as i paid for a bloody pattern item 1st time round!!! suppose its a bit of a happier turn of events, and iv checked and all the holes are obviously perfect on this 1, and the genuine ford bolts fit fine. fingers crossed all goes smoothly, as it should only take a night to get them swapped, then quick etch and seam seal, and get the crossmember and the corners of the bay repainted, good as new

also, whilst out gettin the crossmember, i popped to see my mate phil, n ended up pickin up some bargain bits off him that i need

rs turbo master cylinder (2 outlet instead of my 4 outlet item), gonna drop my freshly cleaned up non abs reservoir onto it once i get it lookin all bufty lol:



completely clear front indicator lenses, been looking for ages, and phil had this brand new pair just lying there:



also was ready to go to ford and order a new header tank and cap, then notice good old phil had 1 brand new still stickered up, just sitting there, so had that away too:



my parts collection is nearly complete now, which is good news

also, when fitting my brake transfer bar, i chipepd some of the gold paint, then decided i didnt really like the gold anyways , so stripped it and painted it yet again, this time in graphite grey:



i hate this bloody car!!!!

[Twins]

[hai07222]

Looking good, good luck with the rest of it.

[RSandy]

finally bit the bullet, dug out the grinders and welder after i thought they were done with, and did this....



bye bye old shitty reproduction crossmember

taking the grinder to a freshly painted car was a bit stressfull and worrying, but i just covered every single bit except the front of the bay, and let john go mad with the grinder...







then once it was out, spent a fookin age grinding and chiselling away at the left over metal/welds..





one all cut out, cleaned up, and ready to rock, the new genuine crossmember lifted in, clamped up, and this time not just lined up with the holes of the various brackets, but fully bolted up in every possible way to act as a complete jig, ready to be welded back in. the good news being that due to the patch work done the last time in replacing the rotten surrounding metal, we now have a nice thick and clean section either side for sum real strong and neat welds, so happy days..













(the brackets and engine cradle were taped up/bubble wrapped cos my bufty self didnt want the fresh powdercoat to suffer any spark damage )

next up, welding, etch, seam sealant, then the crossmember/front panel/front lower part of the bay all get repainted

fingers crossed this is the last time im gonna be using the grinders n welder

[rs_traynor]

looking great mate.cant wait to c it finished. they wheels look awsum bud keep up the hard work (Y)

[RSandy]

bit of an overdue update

first of all, crossmember

having cut out the old, and delicately smacked the new 1 into position and lined up all the bracketry, it was welded into its new home...





then the welds were tidied up and etched...



and then all the weld areas/seams were seam sealed...





and then the important bit, painting it, along with my bonnet hinges which were in primer but had completely forgot to paint previously...

[RSandy]

also, with the front crossmember now back in action and in the correct place , i was able to finish fitting the ARB, the brackets, the gearbox cradle etc



not the best pic cos of shit light, but u get the idea, all new and shiny basically lol

and also fitted up my basic brake set up, obviously minus pads and brake lines, and using filthy discs, mainly just so i can fit wheels to roll the shell around soon...

[RSandy]

wiring loom...

my loom was looking tatty as hell, and wires all over the place, so i grabbed myself a load of split flexible conduit (various diameter), and set to wrapping it all and tidying it up

bag of goods...



and then the loom in various stages from start to finish...













got a few bits still to sort, mainly plugging the alarm back in, but thats easier done with the loom laid, as half the bloody clifford control box bits dnt fit through the bulkhead

also, grabbed me some new bits n bobs..

stack mechanical oil pressure gauge..



steering column repair kit, genuine ford...



bonnet stay plastic clips, again genuine ford bufty spec gayness lol...



and got fixings for bonnet and hinges, and then fixings for headlights and front indicators, and also some fuel pipes for around the tank, all on the way from ford

also fitted my tail lights, although when getting them out of storage after 2 years or so of buying them brand new, i noticed 1 didnt have any fixing bolts, so after contacting nomad, they were nice enough to disregard the fact id left it this long to notice and sent me the fittings i needed free of charge, they even paid the postage, awesome service!!

1 last thing, when fitting my genuien crossmember, 1 of the captive nuts didnt seem correctly positioned, so i ground through the welds to remove and then intended to bolt up and reweld, but it got damaged in the process due to the following...



helicoiled, as standard?! anybody know why this would be? confused the shit outta me anyways, and of course smacking with a hammer to remove the nut damaged the coil, so cudnt use it after. no major issue, just bloody weird and baffling me as to why lol

[marky_g]

oohhh shiny shiny

[boothy]

nice mate..

[BRAMMER]

Great project

[Twins]

well done

[RSandy]

ordered myself some more bits and bobs from Ford to keep the assembly going



new fuel pipes from tank to pump, and from pump and around to front of tank...



fittings for front lights...





and then a set of bolts and washers for the bonnet and hinges...



front end, new headlights and new clear indicator lenses fitted...



rear lenses fitted...



fitted the new header tank...



and dropped my steering column back together with the bushes and bearings replaced with the ford repair kit

[RSandy]

and the progress im most chuffed with so far, rears hubs completed, and wheels on

rear disc conversion brackets bolted into place, rear hubs fitted with new studs, new bearings, new rear oil seals, and even some brand new ford dust caps....



new rear 4x4 discs dropped on...



and then, the most important bit, had the tyres dropped on my wheels, and fitted them on the car, complete with the new polished centre caps from compomotive







so nice to finally see them on the car, and actually see the car looking somewhat like an actual car again. feeling quite chuffed 2nite, loving how they look, be even better when its on the floor and they tucked up inside the arches a bit

[Twins]

[kev 3dr]

I like this mate !!

[Rab]

This is going to be a fucking awesome S2. Fair play, and some tremendous progress there!!

[fezzajsy]

looking good mate

[fatboy billy]

this is looking great just read the whole thread and it looks wicked on its wheels cant wait to see it done

[johnboy19]

looking good like the wheels

[tommytxr]

looks sooooooooooooo good mate

[Mister G]

Just read through this whole post start to finish and I have to say I have the upmost respect for you taking on a project of this scale! A real inspiration for me, though I have to say I break into a cold sweat when i consider whipping out the angle grinder. Still impressed with the paint colour and finish this should look sweet when all back together.

Congrats on a job well done!

[Zetecfiesta]

thats great mate!

[CraigoScott]

looks brilliant, keep up the hard work!!

[martinmilne]

great work mate good progress will be keeping an eye on this one

[Matt Evans]

Great progress. Good to see little Phillys ever full ford stock cupboard getting a hammering as well!

[RSandy]

philly is a permanent life saver i must admit, if he hasnt got it, he knows some1 who has

cheers for all the positive comments every1, must admit iv suddenly become enthusiastic about building it again, and although today i kept gettin intterupted to help my old man with his motor, i did manage to get all the dash area/heater parts refitted and worked out where all the bloody pipes went!

tomorrow, that is wiring loom day, time to lay it around and get things as neat as poss, and maybe drop the dashboard in, hell i may even drop the new steering wheel on too........so long as it dnt get dirty