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

[danny_boy699]

nice work fella, fucking piss take with xmemeber had 1 like that on a fiesta, keep the pics coming and if u don't mind me asking how much was the colum rebuild kit

If you were logged in, you wouldn't be seeing this ad! Register your free account today, or log in if you already have an account.

[Matt carter]

top job mate.

[marky_g]

not keen on the polished lip on the comps mate think it cheapens the look of the car cos so many "max power/halfords special" cars have the black and polished wheels

but nice none the less

[RSandy]

Originally Posted by danny_boy699

nice work fella, fucking piss take with xmemeber had 1 like that on a fiesta, keep the pics coming and if u don't mind me asking how much was the colum rebuild kit

cant find the bloody invoice now, but positive it was something saft like 8quid for both the lower plastic bushes, and the upper bearings, plus the white spacer that sits on the column beneath the wheel boss. saw the same kit on ebay for loads more! proof that ford direct still have some bargains

and cheers for all the comments, and no worries that you dont like the wheels marky g, had them done to make them a bit different, lets not forget i refurbed them 3 years ago so even halfords have had chance to catch up lol. plus theres the 3dr that runs similar comps, n everybody seems to rave about them, so i guess its different strokes for different folks. mine will no doubt end up being powdercoated and losing the polished lips at some point anyways

[RSandy]

long overdue update time

start off with my gearbox, loaded up my 2 old boxes, to take them away to get the rs item rebuilt, and the spare box to butcher for parts incase necessary..



suprise suprise it was necessary mainshaft in the rs box was scrap, so ended up with a big ass pile of crap bits..



but managed to build 1 good box from the 2, retaining the good LSD, and the spare mainshaft, and then treating it to a full refurb with new bearings and seals no pics of the finished 'box, but lets face it, its just the same looking, only now its been painted black lol

ENGINE!!!!

finally got round to throwing it together

will let the pics speak for themselves..





















it was around this time we had realised the oil pump i had wasnt going to fit, at sme point my crank or bottom end has been swapped for a series 1 item, so needed a series 1 oil pump not series 2, so we just carried on building up what we could top end wise

nice new cleaned up injectors fresh from being tested



new nuts and bolts for bolting up pretty much everythin, bufty genuine ford spec



then the engine as it stood for the night as far as we could go with it...











my new oil pump wasnt in stock at PJ motorsport, so whilst waiting i decided to clean up and paint a few more bits ready to complete the engine, even saft bits that will never ever be seen











also got round to cleaning up and painting my turbo, because even though its as new, storing has taken its toll and made it grubby looking, so bit of VHT paint to improve things, however long it stays on for





then of course i decided the gay ass red anodising on the actuator had faded to pink, so that came off, got silvered up, and went back on



few days later my oil pump arrived, n i grabbed a nice motorcraft oil filter to join it on the engine



then finished off the engine









then back at home, with turbo fitted..





fingers crossed a few more nuts n bolts arrive from ford so i can get this thing up on the engine crane, fit the flywheel, clutch and 'box, and get her dropped in at the weekend

[RSandy]

few more bits n bobs that have been happening

centre vent gauge pod arrived back from flocking



managed to bag a minty mint fuel pump bracket and stainless carrier off a dude on here who did me a great deal



new gearbox side engine mounts



got my brake transfer bar and servo and master cylinder fitted up





wiper motor back plate cleaned up n painted, then fitted up with the linkage



then took this pot of bits...



added this..



and came out with bits looking more like this



will be sorting out the various catches n stuff to be plated to keep them fresh

[Twins]

[Kev83]

Andy mate, build looks mint as we disscussed yesterday mate. I have one suggestion mate if i may......get rid of the red boost hoses, dont think they look right mate. I would go for black mate

Keep up the good work fella

[fezzajsy]

looking good mate

[RSandy]

Originally Posted by Kev83

Andy mate, build looks mint as we disscussed yesterday mate. I have one suggestion mate if i may......get rid of the red boost hoses, dont think they look right mate. I would go for black mate

Keep up the good work fella

dude, i would love to have a new set of the black roose hoses, but sadly funds dont allow and iv got a virtually spanking new set of boost n coolant hoses in red, so think im gonna have to stick with red, for a while at least. thats why i chose black n grey for the bay, so at least red hoses would still look ok-ish lol

not the end of the world though, hoses can be swapped at a later date easy enough

[Kev83]

Originally Posted by RSandy

dude, i would love to have a new set of the black roose hoses, but sadly funds dont allow and iv got a virtually spanking new set of boost n coolant hoses in red, so think im gonna have to stick with red, for a while at least. thats why i chose black n grey for the bay, so at least red hoses would still look ok-ish lol

not the end of the world though, hoses can be swapped at a later date easy enough

good lad, you know it makes sense mate. I'll try and pop down soon and have a gander, its just a case of finding time with work, looking after the mother and sorting collecting my evo from APT.

Maybe in a few weeks mate

[Brian]

Looking good mate


Brian

[Tonyt1t]

dribble

[Matt carter]

ding dong

[RSandy]

spent most of today wet flatting the bumpers to get them silky smooth for colour

worst jobs ever, too many curves and grooves to use a block properly, so all about having to sand my own finger prints off during the process lol

then set up the mobile office, no more work van so make do with the daily...



start with the base coat...







then finally after several coats of base, dinner break whilst it dried, then couple of good thick coats of clear, job jobbed...







front bumper come out mint, quick mop when hard and thats sorted, back bumper has a couple of random hairs dropped in, so bit of 1500 luvving and some mopping and will be fine

now im tired, and high on paint fumes, awesome

[Twins]

[Rab]

[RSandy]

fairly big update today, car now has an engine

started off yesterday by finally setting the car down off the axle stands it has spent the past few years on top of, then figured it would be rude not to get it out in the sun to admire it ....







then today got up nice and early, got the car out, and made a start

engine lifted with crane ready for clutch and box..



clutch fitted, box on, plus the flywheel cover etc, and also remembered to add the crank pulley washer n bolt that i didnt have before lol. oh and dropped my new top engine mount on after spending 2 hours pressing the bloody rubber back into it





car up on axle stands, wheels off, bottom arms popped out...



scary bit, engine hanging rather high off the groud, directly above the nice shiny paintwork





after a fair bit of shouting and swearing, and pushing n pulling the engine all over the place...





then after the driveshafts pushed home, gear selectors bolted up, bottom arms back in place, wheels on, and car on the deck, we decided we really shud fit the bonnet, be rude not to...









and 1 final shot of the engine in its new home with the turbo and master cylinder bolted back up...



must say 1 thing, our estimates on the new bonnet vent clearance pushed it a bit, with it shut and roughly in position height wise, the bonnet vent slats clear the crossover pipe fins by about 2mm but yeah, we meant that honest lol

good days progress, and proper chuffed with the outcome after all the stress and swearing

[Arne]

Lovely car. Really nice with the mallardgreen og it.

[Rab]

Thats looking very nice!

[Brian]

Looking really good


Brian

[Oranoco]

Awesome!

[massivewangers]

Looks awesome out in proper light! Bonnet looks great too. Should look excellent when it's done

[Lo@der]

Good project this, top work

[Jumbo]

About time you got it out the garage

Looking good mate, keep at it.....oh and watch out for Coley going past your house, he's got the car back out now so be careful!! He's known to many of us as right foot Coley lol!! Says it all really

[Kev83]

looking good andy mate, making some nice and steady progress no mate, well done

[RSandy]

Originally Posted by Jumbo

About time you got it out the garage

Looking good mate, keep at it.....oh and watch out for Coley going past your house, he's got the car back out now so be careful!! He's known to many of us as right foot Coley lol!! Says it all really

haha will keep my eyes open then scott, so long as he dont do it early sunday morning spec n wake me in a hungover state, i will look forward to it

cheers for all the comments people, much obliged

[Twins]

That looks great

[muz]

Mallard green looks awsome on the Series 2! Loving the bonnet vent as well.

[AquariousRS]

Very nice build and a credit to you and your mates for all the graft put in.

[Brookesy]

Love that bonnet

[frayz]

Colours looks stunning on that mate.

Great job

[nickscunny]

one brilliant thread mate - keep up the geat work..........

[marky_g]

such a cool colour

[COLEYST200]

Nice to see your Know getting on with the build i will have to pop up again and have a look . and im loving the ((( right foot Coley ))) bit

[Puss2]

superb project

[Glenn.]

Wow thats really nice.Top work there mate.It will soon be finished.

[stuart collins]

looks really good

[rs1072]

Very nice

[stembo21]

looks ace mate keep it up