Thread: Series 1 No Expense Spared Resto
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Old Apr 1, 2013 | 02:22 PM
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Cheezy1
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From: Greater Manchester
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Day 6 + 7 - With the long Easter break what better time to spend a couple of days working on the car.
Well i kind of wish i hadn't, what i thought was a good shell turns out to need more work than i thought, well quite a lot actually.
I began by taking the outerwings off and decided to get the car down to part metal to see what i was working with.
When i bought the car I noticed the carpets in the footwells were wet, the seller said it was the Heater Matrix but suspected the gutters from the sunroof were blocked. After stripping the car I was soon aware the sunroof gutters were blocked and had resulted in the build up of water in the a posts and footwells causing a nice hole in the drivers side footwell/bulkhead.
With the outer wings now off I soon noticed the passenger A post was a good mixture of filler and rusted metal, alot of filler I should point out. Someone had tried to temperally fix a very rusted A post.
The passenger side A post is a mess and will need a new inner and outer skin.
A nice hole at the bottom of the passenger wing adjoining the A post.
The bottom of the A pillar has a small rusted hole.
The rear passenger arch has had a previous repair - nothing too serious.
A few small pitted rust holes in the passenger rear quarter.
A hole in the outer passenger sill - new one now on order.
Both footwells are screwed as a result of the blocked gutters - new front foot pans on order.
Small hole in the drivers side outer sill
Brake servo mounting point on the bulkhead is very weak.
Small hole below the battery tray.
Two small holes in the bootfloor
Hole behind the drivers seat.
Other than we are all good.

Ive come to conclusion old Ford's are very good at hiding rust.

Drivers Side Footwell, its worse than it looks


Hole just below seat belt anchorage


Very soft around the brake servo mounting, and a next to the battery tray


Not so nice passenger A post

Repair to rear passenger arch


Sourced a good non rusted bulkhead, should save alot of time, time to repair the footwells, both a posts and lower inner wing.

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