my evo 5 rebuild, cossie on hold :(
06-01-2013, 11:39 PM
#1
my evo 5 rebuild, cossie on hold :(
copied from mlr so please ignore some of the text, my escos has been put on hold due to me doing this 
well after 2012 being the worse year of my life, december hitting me very hard with so much bad stuff happening i didnt think anything could get any worse
well on boxing day i ended up crashing my evo after driving like a total tool becuase of everything happening i hit a bridge so only myself to blame
i couldnt see the full extent of the damage until it was in the garage which revealled, bumper,wing,screen, both air bags, steering arm, ball joint, and the drive shaft popped out, and the car drove home the 6 miles or so lol, which after driving it home made me think the car wants to live
after looking into the damage it never touched my doors or headlights, and no chassis damage anywhere, so i got straight on stripping it as this was my point to do the full build on it, sorry for lack of pics just been busy with it, but ill start to get pics from now on
so the car as it was before the crash
after the impact, and in november, i done single headlight conversion, breather system and cam cover, got the clear and red rear garnish lights and modded them into foglights, as well as modded the decat so the exhaust fitted, new external wastegate and screamer pipe, batt in boot location, done loads and was running spot on
so the strip down, this will be a full build, so ill be asking loads of questions in the forum to get help and advise as well as evos are still new to me, the car is now a bare shell, and i made a frame to roll it on its side to get the floor back to bare metal, and had to do a couple of bits of welding to the chassis legs, removed inner arch hanger front tow hook, rear will be removed as well, batt tray has gone from engine bay, also took the lips off the rear arches and the lips off the inner front arches to compensate for wider wheels, already running 9.5x18, but you will see as the car starts to get built as ill doc everything i can, the rear arches have been rubbing on inner door shuts,so need to look into this to see what i can do
sunburnt from welding the frame up lol
back to metal
thats all the pics i have, more as i do more work now, ive ordered some rust bullet which will be applied first, then it will have sealant and brushable seam sealant in places as well as stone chip then paint and laquer, then the car will be back on stands so i can get the arches boot floor and engine bay painted
then will start with rear beam first as i need to get it rolling before i can do the paint work
well after 2012 being the worse year of my life, december hitting me very hard with so much bad stuff happening i didnt think anything could get any worse
well on boxing day i ended up crashing my evo after driving like a total tool becuase of everything happening i hit a bridge so only myself to blame
i couldnt see the full extent of the damage until it was in the garage which revealled, bumper,wing,screen, both air bags, steering arm, ball joint, and the drive shaft popped out, and the car drove home the 6 miles or so lol, which after driving it home made me think the car wants to live
after looking into the damage it never touched my doors or headlights, and no chassis damage anywhere, so i got straight on stripping it as this was my point to do the full build on it, sorry for lack of pics just been busy with it, but ill start to get pics from now on
so the car as it was before the crash
after the impact, and in november, i done single headlight conversion, breather system and cam cover, got the clear and red rear garnish lights and modded them into foglights, as well as modded the decat so the exhaust fitted, new external wastegate and screamer pipe, batt in boot location, done loads and was running spot on
so the strip down, this will be a full build, so ill be asking loads of questions in the forum to get help and advise as well as evos are still new to me, the car is now a bare shell, and i made a frame to roll it on its side to get the floor back to bare metal, and had to do a couple of bits of welding to the chassis legs, removed inner arch hanger front tow hook, rear will be removed as well, batt tray has gone from engine bay, also took the lips off the rear arches and the lips off the inner front arches to compensate for wider wheels, already running 9.5x18, but you will see as the car starts to get built as ill doc everything i can, the rear arches have been rubbing on inner door shuts,so need to look into this to see what i can do
sunburnt from welding the frame up lol
back to metal
thats all the pics i have, more as i do more work now, ive ordered some rust bullet which will be applied first, then it will have sealant and brushable seam sealant in places as well as stone chip then paint and laquer, then the car will be back on stands so i can get the arches boot floor and engine bay painted
then will start with rear beam first as i need to get it rolling before i can do the paint work
06-01-2013, 11:49 PM
#3
it was the last thing i could lose to finish my year off and even then i had shit luck on new years night lol
but onwards and hopefully upwards, the car wont look like it used to anymore asi already had plans before xmas on what was beind done to it and ordered some stuff which turns up tuesday
but onwards and hopefully upwards, the car wont look like it used to anymore asi already had plans before xmas on what was beind done to it and ordered some stuff which turns up tuesday
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07-01-2013, 12:18 AM
#9
yeah they soon went, i got blocked in my 4 old bill cars, 2 insignias, bmw and a 400bhp supercharged jag xf lol, becuase there was a black scoobie with green wheels done some sort of robbery and i was in the wrong place wrong time, until one copper said its an evo after reading the sticker on the door, so went a bit more stealth
07-01-2013, 12:26 AM
#11
yeah, this has to come first, the cossie is a long term project ive had it 4 years and its way having the last bit of work done to shell, this was my daily so im back in my mondeo now which i may sell and buy myself a rs2000 instead
but ive got my plans for this car so will be interesting when its done
but ive got my plans for this car so will be interesting when its done
07-01-2013, 09:04 PM
#12
just had a tidy up today, but now garage is clean took some pics of the work been done
whats left of the wheel after impact, still dont know how it drove home, maybe dragged itself lol
underside almost there now
rear exhaust hanger that goes into rear arch has been removed
rear arch lip gone, still want to open the arches out more but stick on something in next pic
this is where my rear wheels were rubbing, downside is its the door shut that comes into the arch, so i need to find a way of chopping it out and keeping the door shut looking good
rear brake pipe holder had a snaped captive, had to chop it off and make a new piece as grinder wouldnt get in there to take captive of
rear chasis leg had 3 holes in it, so cut out and repaired
battery tray brackets removed
random shot of the car inside on its side, and windscreen sort of removed
front panel all cleaned up
and a random shop of the car ready to have its rust bullet on if it turns up tomorrow
and hopefully tomorrow my bits ordered before xmas turn up, but pics of them will be up tomorrow
whats left of the wheel after impact, still dont know how it drove home, maybe dragged itself lol
underside almost there now
rear exhaust hanger that goes into rear arch has been removed
rear arch lip gone, still want to open the arches out more but stick on something in next pic
this is where my rear wheels were rubbing, downside is its the door shut that comes into the arch, so i need to find a way of chopping it out and keeping the door shut looking good
rear brake pipe holder had a snaped captive, had to chop it off and make a new piece as grinder wouldnt get in there to take captive of
rear chasis leg had 3 holes in it, so cut out and repaired
battery tray brackets removed
random shot of the car inside on its side, and windscreen sort of removed
front panel all cleaned up
and a random shop of the car ready to have its rust bullet on if it turns up tomorrow
and hopefully tomorrow my bits ordered before xmas turn up, but pics of them will be up tomorrow
Last edited by xr4x4rs; 07-01-2013 at 09:06 PM.
08-01-2013, 11:07 AM
#18
rust bullet is a paint that eats into rust and drys it out, they gurantee it for 10 years
just brush it on, then can be painted over undersealed etc, as the evo ddoesnt come with any sealant on it the floor has took a beating over time, so im just making sure it lasts
can get it direct from rust bullett and uk website and the bloke is very helpful though its not cheap
just brush it on, then can be painted over undersealed etc, as the evo ddoesnt come with any sealant on it the floor has took a beating over time, so im just making sure it lasts
can get it direct from rust bullett and uk website and the bloke is very helpful though its not cheap
08-01-2013, 11:18 AM
#21
Ben
You drove it home with the wheel like that? 
Looking good so far mate.
Looking good so far mate.
08-01-2013, 11:22 AM
#22
those wheels cost me 460 new lol, i sold one of my escos and bought this car, i never even viewed it, just sent my mate to scotland and got him to drive it back lol, its been so reliable its unreal with one failure in just over the year ive had it which was a crank pulley snapping due to the rubber insulation as its a harmonic balancer, cost me 70 quid to repair, serviced regular will last ages at sensible mods
with the rust bullett, i got the automotive stuff as it has more aluminium in it, but he did say i should of got the std stuff as its a thicker coating for the underside
i got the 2 pints which should just be enough to do the underside of the car with two coats, im not going to to the arches as they have good sealant already, so will just clean stonechip and paint those
with the rust bullett, i got the automotive stuff as it has more aluminium in it, but he did say i should of got the std stuff as its a thicker coating for the underside
i got the 2 pints which should just be enough to do the underside of the car with two coats, im not going to to the arches as they have good sealant already, so will just clean stonechip and paint those
08-01-2013, 07:50 PM
#25
been a busy day again today
my mate who has been helping me strip, and sand the car came round again today so we could finish off the sanding as the rust bullet turned up in the post today
having to wait for paint to dry is a boring job lol
the rust bullet
2 coats applied, only used just over 1 tin which was good, shame it took all day to do after waiting for the first coat to dry
then it was time for the sealant, downside is i never read what the paint supplies gave me, i just asked for paintable sealant lol, this is actually polyurenthe adhesive sealant, which will dry like a rubber, which is better than what i planned just a nightmare to spread hence the mess
replicating the big sealant in the engine bay and also on the back floor pan
and i bought this today for the sealant, so much easier to use than a hand operated one saved me a lot of time
so now to leave it to dry and set, and tomorrow is to apply the stone chip
my mate who has been helping me strip, and sand the car came round again today so we could finish off the sanding as the rust bullet turned up in the post today
having to wait for paint to dry is a boring job lol
the rust bullet
2 coats applied, only used just over 1 tin which was good, shame it took all day to do after waiting for the first coat to dry
then it was time for the sealant, downside is i never read what the paint supplies gave me, i just asked for paintable sealant lol, this is actually polyurenthe adhesive sealant, which will dry like a rubber, which is better than what i planned just a nightmare to spread hence the mess
replicating the big sealant in the engine bay and also on the back floor pan
and i bought this today for the sealant, so much easier to use than a hand operated one saved me a lot of time
so now to leave it to dry and set, and tomorrow is to apply the stone chip
08-01-2013, 08:47 PM
#30
yeah shell is straight mate
passenger door was out by 2mm, but when push would shut, looked into it and its a dodgy catch lol
ive measured acorss 4 points diagnally and all were same from point to point, no marks on front doors nothing no creases no sealant or welds broke on any strutcal parts
wheel took all impact luckily
passenger door was out by 2mm, but when push would shut, looked into it and its a dodgy catch lol
ive measured acorss 4 points diagnally and all were same from point to point, no marks on front doors nothing no creases no sealant or welds broke on any strutcal parts
wheel took all impact luckily
09-01-2013, 04:21 PM
#34
Too many posts.. I need a life!!
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Sorry to hear that Rich.At least you are still in one piece though as cars are easily rebuilt unlike our fragile bodies lol.
The cossy is still coming along, I've almost got the engine in it now. Just waiting for the last few parts to turn up then I can put it in.
The cossy is still coming along, I've almost got the engine in it now. Just waiting for the last few parts to turn up then I can put it in.
09-01-2013, 08:58 PM
#39
Advanced PassionFord User
Quality rebuild 
good luck with the project.
good luck with the project.
09-01-2013, 09:21 PM
#40
today was start of the painting
so car was masked up where the stone chip wouldnt be applied, mainly around bolts, and where subframes and tank would be, and the centre section
stone chip applied
and masking taped removed
will remask the wholes and studs later on, then tomorrow will be paint and laquer and the floor pan will be ready, have bought clear wax oil as well so ill spray that in all the chassis legs and every place hidden, then it will be back on axle stands friday ready for arches, engine bay and boot floor to be prepped and painted, then stuff can start to go back on the car
so car was masked up where the stone chip wouldnt be applied, mainly around bolts, and where subframes and tank would be, and the centre section
stone chip applied
and masking taped removed
will remask the wholes and studs later on, then tomorrow will be paint and laquer and the floor pan will be ready, have bought clear wax oil as well so ill spray that in all the chassis legs and every place hidden, then it will be back on axle stands friday ready for arches, engine bay and boot floor to be prepped and painted, then stuff can start to go back on the car