Ford Racing Puma - Underbody Restoration

[williamsclio]

Ok a quick hello to you all Been trying to register on the site for sometime but finally i'm here I will add below all the stages i've done so far on my restoration of my FRP314. Open to ideas and pointers along the way as this is the first time i've ever attempt something to this scale. Unfortunatley about 6 weeks ago i had some random seizures and it looks as tho i wont be able to drive for a YEAR So decided i would take advantage of the time and resto the underside of my FRP. I had a full respray some months back and i decided i would love to get the underside back to new David

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[williamsclio]

Not a full registered member as yet so thought i would add my spray job photos in this section. :shock:
Car went in Wednesday went to pick up this evening but my mate decided to spray my doors and wing mirrors and not just the bonnet, wings, bumper and rear quater panels as we first agreed, not that i mind as he decided to do it off his own back (going to give him some extra money as the price he orginaly quoted was a bargin and he has done extra.)
He was just mopping it as i arrived so wont be ready till tomorrow.
Collecting the mudflaps in the morning, wouldn't dream of leaving the body shop without them fitted after seeing how imaculate the paint job is
First photos are picture messages he sent me so picture quality not brilliant.
Pictures of him mopping are taken on my iPhone so a little better but not brilliant, but i think you'll agree just from the photos you can see how good it looks.












I think its safe to say i cant wait till tomorrow

[williamsclio]

Few more photos of the final stages. Again photos taken with iPhone so not brilliant, need to get digital camera.





First photo in the sun Dont want to put plate on looks sooooooo good without it 8)



Photos taken after a good few hours of polishing this afternoon.

[neil73]

nice!

[williamsclio]

Ok all the time has started to protect the underside of the car. I hope my updates help others also looking to protect there car for years to come. Open to ideas and suggestions along the way as this is the first time I have attempted a task to this scale.
At lunch time today I had an hour to burn so decided to make a start on the back box, even tho in the next few days I will be removing it fully to seriously tweak.




After coming across the forum peojectpuma I saw Jacko had started selling short stainless steel bars that fit in the Miltec exhaust to make them look similar to the standard exhaust tip so as that arrived first thing this morning I found 5 mins to fit it, took a little tweaking of the bar but with a gentle tap tap with the hammer all is well,

Personal I think it looks fantastic such a little modification but gives it that standard look. He’s currently selling it on ebay if anyone else is interested.
http://cgi.ebay.co.uk/ford-racing-pu...item2557129f37
I’m fortunate enough to have a garage but its not much wider and longer than the car so its very tight for moving however once under the car space is not an issue its just getting under the car that’s the problem.


Ok started by jacking up the car and putting under axle stands

Photos of the rear carriage of the car, the majority of rust is surface however there are areas were its getting worse.




Removed heat shield


Will be replacing as its cracked in the middle and has seen better days.
Photo of the corrosion under the back box heat shield

Photo of the two bolts holding the heat shield in place.

Quick tidy up with a wire brush

Cleaned the bolts up and sprayed in satin black.

More to come tomorrow.
Not to sure on what product to use, but going towards smooth finish black hammerite on this section, any arguments against or for?????
All comments welcome
David

[williamsclio]

ok small update spent a couple of hours on the under side witha variety of wire brushes, preparing the surface for protection and paint only managed to do a smallish section so far.

and i've had the exchaust in the lounge for the last couple of nights (to the misses delight), spent around 3 hours on it so far, slowly getting there.
So from this:

to this (so far):

Didnt realise my friend who owns the body shop has a sand blaster so will make life so much easier to prepare the hubs etc for painting once i get them removed.
David

[williamsclio]

if you cant beat them join them
Bit of x factor and a back box

David

[williamsclio]

ok found a bit of time this evening to do some more on the car, so decided to remove the rear bumper and turn the car around in the garage as to give me more room to work.
carried on stripping the underside but wont update pictures untill a large section is complete and ready for primer etc
Been a busy week but hoping to get lots done over the weekend.



when I started the car to move it out the garage I forgot the back box wasn't on WOW loud noises
Now I know all cars sound stupidly loud with the back box missing but Jesus what a noise the FRP makes.

David

[williamsclio]

Ok little update
Managed to clear the garage out today, there was a running machine, loads of old carpet, underlay and loads of boxes at the front of the garage, so found space in the shed for the boxes carpet etc and put the running machine in the spare bedroom.
By moving all of the above I managed to move the car another 2 foot further in to the garage so now I can leave it jacked up and not have to lower it to close the garage door. Result

So now the car can stay up on the jacks I took the wheels off and started to clean the wheels, which gave me a chance to final use my new power hose purchase and poor boys wheel sealant.
No before photos but they were pretty filthy on the inside but nothing the cherry wheel cleaner, Maguire’s brush couldn’t shift.
Hoping to finish off the other wheel tomorrow and may remove the rear beam etc (time permitting).



Got a replacement centre cap for this wheel as i sprayed TFL on the wheel a while back and didn't rinse it off properly and it stained the cap
Plus the dreaded xfactor was on again so was another chance to rope the misses in to another couple of hours on the back bax, half a tub of Meguires NXT metal gone

David

[williamsclio]

Sundays 22/11/2009
Finished off cleaning the second wheel and applied poor boys wheel sealant.


Put with other in the garage with some bubble wrap over them.

Started to remove the rear beam, managed to remove the two brake callipers, discs and the bolts holding the suspension arms on, but due to my limited tools I couldn't undo the following rear beam bolts,

very frustrating as would have been nice to taken it fully off this evening, hopefully friend popping over tomorrow night with the extra sockets etc that I need.
Spent another 20 mins with the wire wheel brush attached to the drill.
Few random shots



I’m slowly realising quite how much is involved with this project but as I have a year ahead of me to do it I’m no rush and enjoying each time I have some time to work on it.
Right almost time for another hour on the back box
David

[williamsclio]

Monday 23/11/09
OK managed to have a good giggle with a few mates tonight whilst trying to remove the rear beam and fuel tank, it was the first time for all of us so was quite a learning curve :shock:
had one of the rear beam bolts rounded on us however after some action with the hammer we eventually got the rear beam off.
So first off the centre section removed and another heat shield.


Rear beam removed after a good half an hour fighting the bolt

OK ready for the fuel tank removal

Would like to note there was only an 1/8 of a tank of fuel left however just so you know that’s still quite a lot lol
So after some fiddling we got it off whilst the two pipes that go in to the top were dripping on the floor.


Think the fuel got to us a bit as we found the name of the pump highly amusing

And finally just a random shot of the arch, think I’ll be starting on this tomorrow evening.

David

[williamsclio]

Thursday 26/11/09
Final removed the rest of the rear end, callipers, suspension, fuel black box and the fuel pipe the whole area now ready for stripping.


You can see that the rear brake lines are still attached as I’m waiting for the brake fluid to empty before removing.
To remove the suspension I had to gain access to the top nut in the boot so decided to remove the carpets etc (something else to tweak indoors)

Now everything has been removed I can assess the rust, it appears a little worse than I was hoping but nothing to major, I should hopefully be able to rectify without to much hassle.


As I haven’t taken on a task to this scale before I thought it would be worth taking note of were everything came from

After some web searching today I’ve found a local electro plating company
http://www.trentonelectroplating.co....troplating.php
and after a quick call to the owner he has told me it will cost in the region of £25 to have all my bolts, nuts etc plating in zinc.
David

[williamsclio]

Double post

[williamsclio]

Saturday 28/11/09:
Went out last night and had a few drinks so didn’t manage to get a lot done today, had planned on getting the suspension taken apart and the rear beam but didn’t get to mates garage before he closed.
Got the power hose out and spent half an hour cleaning up some replacement second hand inner front arch liners I bought a month ago. Come up really well. Will compare to the front two once removed and then replace with the best ones.
Unfortunately the camera wasn’t charged so poo photos as taken with the iPhone

Also jet washed the fuel tube.


Used some cheap plastic cleaner and has come up like new.



Removed the metal bit from the top of the fuel pipe as will send this away for zinc plating with the rest of the bolts.

(RPOC & PROJECT PUMA)
Does anyone know the Ford order code for the rear brake lines?

David

[williamsclio]

Saturday 28/11/09
Cant help myself




David

[Paul_RS]

I've always fancied one of these cars

Looking forward to further updates mate!

[williamsclio]

Sunday 29/11/09
Not really done alot today. To much football




Looking forward to Tuesday as taking rear beam etc to powder coaters
David

[williamsclio]

Monday 30/11/09
Ok brake lines removed, however my lack of experience showing again here,
Please can someone tell me how to remove the hose section to the brake calliper?

Trying to get it removed to give it a tidy up, as had original planned on replacing but new ones £70+ and I think I can get these looking pretty much new.
Lines in the lounge ready for a clean up, getting some Jenolite rust remover for the nuts on the ends as they have seen better days.

Also taking the rear beam and tank etc to powder coaters tomorrow and I would like to get the rear callipers shot blasted and powder coated in silver.
First of all is this something that anyone has had done before and if so should I strip them down? (ie ever nut and bolt?).



Also should I cover the holes up, advice required please.
And should I be looking to remove this? If so how as cant get it to budge.

David

[williamsclio]

Tuesday 01/12/09 (some pictures with iPhone again so poo)
Ok managed to achieve a lot today, got up early (ish) and removed the last part of the brake line (thanks to Flash for instruction)

Also decided to power hose the rear arches in preparation for stripping back:
Placed large plastic sheet on the garage floor to stop the floor getting covered in water sprayed the arches with engine bay cleaner and left for 5 mins before attacking with the power hose.

A lot of dirt still left tucked away in the upper arches as can be seen on the sheet after the wash.

Took pump out of fuel tank and tipped the rest of the remaining fuel in to friend’s car.

Spent some time on the rear arches with the angle grinder to try and remove the rusted areas, not finished as yet but made a good start.
Before:

After:

Random Arch:


Took rear beam down to friends garage so he could take them apart.


However he told me that there is no way he could remove the rear ABS sensors without braking them  so before he did, he told me it would be worth getting a price on a replacement one wait for it ………………………… £118 plus the VAT 
So for now he has taken it apart but hasn’t taken out the ABS sensor (therefore all the parts linked together), until I decided what to do about it. Rang Puma Build spoke to a very helpful employ who explained to me in all the years he has worked on the Racing Puma he has only ever got one off without it breaking.
So the options:
1. Remove the old one so all the parts can be taken to shot blasters and powder coaters and replace the ABS sensor even though the one on the beam works (at a cost of £118+)
2. See if the shot blasters and powder coaters can work round the problem with leaving the sensor attached. (Unlikely but worth asking)
Whilst there he took the springs off the suspension so now there ready for powder coaters. As for the damper I’ll have to clean this up by hand as been told cannot be shot blasted.

Whilst there I got his other half to order me some seam sealer in.
Decided to go to Halfrauds for some bits and bobs.
Got back and attacked the rear callipers with some paint stripper, worked pretty well but still took some good old elbow grease to get them ready for painting.


Only painted part of the calliper so far, but adding layers to the main part over the course of the evening. 

Whilst at Halfrauds I bought some

I have put all my bolts, rear discs etc in the bucket for the night hoping to remove the majority of the rust in preparation for the zinc plating.

David

[williamsclio]

Tuesday 01/12/09
Finished of spraying the rear callipers, really happy with the results
During:




Afters:

David

[Zetecfiesta]

shiney shiney!!

[williamsclio]

Wednesday 02/11/09
Took brake discs out of the bucket and surface rust has all been removed 
All other bolts and nuts etc looking pretty good as well however leaving them in for at least another 24 hours as some of them still a bit rusty. Thumbs up for the hammerite rust remover, I did think to myself how effective could it actually be putting already rusty nuts etc into a bucket of water, however true to its name its certainly done the trick. 
This is the discs after being taken out of the bucket and dried off.

Both masked up for spraying.

After photos



Another part stored in the kitchen ready to be put back on.
David

[williamsclio]

Wednesday 02/11/09
Ok saving the pennies all over the place, picture of the hand brake cable plastic brackets and brake line holders.
I've put the hand brake cable brackets in to the bucket to try and remove the rust stains, not sure if the replaement hand brake cable im getting will have replacement ones but we'll see.

Cleaned up the brake brackets with good old WD40 and a old toothbrush.


David

[williamsclio]

HOPE YOUVE ENJOYED THE READ SO FAR,

I'll keep the updates coming

As said at the start open to suggestions

David

[wrx-maniac-22]

Very nice.Looks like you are doing a cracking job there.

[andy130]

never fought they rusted that bad, paint job looks mint, keep up the good work

[Twins]

great job there ,well done

[williamsclio]

Originally Posted by andy130

never fought they rusted that bad, paint job looks mint, keep up the good work

Yeah car coming up to ten years old and only done 80,000 miles.

Glad ive started now as think i've caught it just in time as it mostly surface rust.

David

[Puma_dal]

Fancy seeing you over here David

Great work

[williamsclio]

Originally Posted by Puma_dal

Fancy seeing you over here David

Great work

I couldnt resist the most popular Ford site, many Ford owners have taken on projects like this and all the help i can get the better

David

[Munch]

awesome cars just a tad underpowered

[williamsclio]

Originally Posted by Munch

awesome cars just a tad underpowered

Couldnt agree more, as tempting as it might be to put a Cosworth lump under the hood I wont be as this one is staying standard.

Next car will have enough BHP tho, in two minds at the moment wether or not to get a Escort Cosworth or an Evo 6 Tommi Mac (thought i'd decided on the Mac but i keep changing my mind)

The third car on the drive to join the FRP and one of the above will be a NSX Type R thats for certain, however that might be in a few years to come

David

[CosKev3]

Great thread,great work.

Epoxy Mastic121 is great to use,and highly recommended by Classic Car rebuilders.
Also Dinitrol Cavity wax I can recommend for inside doors/quarters/box sections etc.
And Dinitrol Rust converter.

http://www.rust.co.uk/epoxy-mastic.cfm

If you can be arsed take a look at my 309 resto,link in my sig,all three above mentioned products used.

[williamsclio]

Thanks CosKev just looking through your restoration, fantastic read and stunning final results.

Was just about to but the Epoxy Mastic 121 in grey (starter pack) looks like its excatly what i've been looking for

however £25 seemed pretty resonible however went to the basket and it added £8 delivery and £4.94 vat totaling £37.89, what area can i expect to cover using this as if i'm to spend almost £40 need to know it will cover a decent area?

David

[CosKev3]

Thanks for comments,got a Xsara 2ltr 16v lump I'm rebuilding to drop in now,think she will surprise a few cars then with circa 167bhp!!!!!!

I used 2 ltrs on 309.
Its very good stuff to use,goes on well,dries nice and smooth,and is very hard finsh once gone off.
Just don't mix more than you can use in an hour,it starts going off and is hard to use then.
I found an aerosol lid of paint and hardener mixed was a good amount to mix up.
My m8's doing the underside of his Evo V with it,and goes on very well with a gloss paint mini sponge roller.

[stuboy]

u like to work hard..

surprised at the amout of rust though..

[Paget]

superb work so far mate. i had one of these engines in my fiesta, loved it.
keep it up

[colarado red]

nice work

[Robs Frst]

Very nice,
Always fancied having a racing puma from my standard puma, Handle very well.

[CaftDunt]

Awesome project. Love FRP's!!! Will be keeping my eye on this thread