Hi all. New here on Passion Ford but a regular on WWW.ESCORTEVOLUTION.CO.UK. Thought I'd share my long running project with you guys. Not one for the motor heads among you but more for the people who prefer the body styling side of things. My car is a 96 1.6 lx. Always loved the lines of the cossie (who doesnt) so decided to work them onto my 5 door. At the start of this project I had never seen them on a 5 door which is why I decided to do it
The full thread is on Evo but I'll just upload pics of the more interesting bits on here. I wont fill it with loads of commentary so any questions just ask. They may also not be in the correct order i did it all but nevermind

I dont actually have a start picture but it was just like any other pepper red scort out there!
Front arches already fitted, You can also see how dirty the engine bay is And please excuse the neon light tube........yes the car had been in that...era!





Rear arches/ Expanding foam/ fibreglass and Filler. All the ingredients a man needs.












Right, think these were all the main stages of the arch assembly. This took me forever to do and a tonne of filling sanding and repeating! Ill upload more as I go, I wont bombard the 1st post with every pic I have lol
Comments helps and tips ALWAYS welcome. I always like to learn something new. Cheers.

 

makes a change from the norm,i am no expert but it looks like you are doing a good job,so good luck with it and keep the pics coming.

 

There's another guy doing something similar on here, but with far worse results (his appears to be destined for the scrap yard judging by some of his past efforts he posted up). 10/10 for effort and workmanship Keep it up!

Are you looking into de-handling the rear doors?

 

Cheers mate. Everything I touch I have to modify lol Gotta make it unique, built not bought is the order of the day!

LOl cheers mate.........got a link????

 

Deep breath.........


https://passionford.com/forum/restor...it-5-door.html

 

Its ....its....uncanny! Apart from the application of filler using what must be a fork lol

Heres a couple more I forgot to add of the arches in the eralier stages. The stages where you think 'what the hell have i done'!? I hope people dont mistake my thread as a copy of his lol, Mine was started on Evo a long time ago.

 

Time for the repair and general sorting out of the rear bumper and the shocking spats i ended up with! Sorry its blurry, but the sort of scratch lines you can see are in filler! It arrived slapped in filler and sprayed over.........and there wasnt even a repair under it when I buzzed it all off!

This one has countless layers of paint and numerous cracks. The drilled holles are to stop the cracks spreaking further, then to be filled and primed.

Bumper had slight damage too. Not from me but from previous owner. Somebody repaired it badly. At the bottom where the 5 or so sections are the far left had been sprayed without proper preping. The current paint had just flaked right off

 

Time to see what the next challenge is. Hmm, better do something about that gap we now have thanks to the wide arches.

Excuse the pic the wrong way, I did edit it on photobucket but it still wants to come out the wrong way!
One donor bumper section.


And with spats in place, jobs a goodun'

Excuse the state of the inside lip on the arch. This will be trimmed up towards the end.
Skirts also trial fitted here.

Also here I've already preped and primed all the door shuts and doors inside and out accompanied by a lovely guide coat.

Comments welcome.
FULL THREAD @ WWW.ESCORTEVOLUTION.CO.UK

 

Coming along nicely

 

Time for the wheel refurb. I would like new alloys at a later date but not so flush at the mo, so i just gotta roll with what I've got.





And times this process by 4 and what do you end up with?


Also got a Magnex 3" tip exhaust from a guy on the site.


And after a bit of work.......


More to come later.
Full thread at WWW.ESCORTEVOLUTION.CO.UK

 

Time to strip down the rear disc beam to replace the shody drums.


These had seen a lot better days!


Beam had been sandblasted at work and hammerited. Calipers and ARB had the same treatment. Calipers were rebuilt with new seals all round.



Also, an upgrade for the front. The usual st170 discs and Mondeo calipers. This is how they had arrived!



After the sandblast treatment.



Took the arch liner out and gave the arch a little clean. Brakes all fitted with my spacers ready for the wheels to go back on.


Full thread @ www.escortevolution.co.uk

 

i didnt expect to see such good quality of work when i clicked on this but you seem to be doing a good job hope it looks really good when youre finished mate

 

Nice to see something different for a change.

 

Nice idea with the rear bumper, are you going to fill it and run it, or take a mould and fit a fibreglass one?

 

As it is mate. Its actually all primered now. Not worth making a mould for a solid fibreglass one. I don't think the weight saved would help my whopping great 90 bhp!!!! I wanted to use standard bumpers too to be different. I'll get some pics up soon of the front.

 

Nice work fella, looking really good, loads of work going in, will pay off

 

Update time. Bank holiday weekend resulted in my skirts almost finished. Main part was to rub in the bottom of the doors into the skirt smoothly.







Please ignore the lights, I've standard ones to go on Also the fuel cap will be sprayed body colour or rubbed down slightly ( brushed alu)



As it stands now. Few bits more to fill and smooth then the body is ready for some prep work. Ill leave the bumpers to last, I just want to get the body finished 1st as thats the biggest hurdle.

Comments welcome. Full thread @ www.escortevolution.co.uk > Show Us Your Motor > Wide arch 5 door project.

 

your doing a great job there mate, looks good.

 

in all fairness its alot of work your doing but looks to be a good job. hope no cracks start appearing

 

Cheers mate

Cheers mate, arch panels shouldnt crack. There stuck on a treat plus its not an area that has lots of flex like the skirts. I will, towards the end use a thin grinder blade to make 'joint' lines in the skirts where they usually are. I filled and smoothed everywhere to make sure it all flowed nicely but was always gonna put so called 'joints' back in there to minimize the possibility of stress cracks.....it just better work

 

Very impressive work there, nice to see some hard work, fair play

 

Not usually my cup of tea, especially a 5 door, but you're quite the dab hand with the filler! Very nice work mate.

 

must admit like a few others have said i wasnt sure how a 5door cosworth was going to look but you realy have done it justice!

top notch work.. im begining to think that if ford was to make an escort cosworth today it would be a 5door and would look similar to what you have done..

a few of the fiestas what are rallying or hillclimbing these days are 5doors so a 5door escort doesnt seem that crazy anymore!

http://hooniverse.com/2010/12/01/rar...recked-fiesta/

http://www.lincah.com/2009-ford-fies...eak-rallycross

 

I really like this car is different but with great attention to detail and im really liking the colour scheme with the green calipers and black rear beam.Keep up the good work I shall be watching this with great interest

 

The insides of the front arches all finally smoothed out. This took me ages, with finding more holes to fill and sand down again! Iv'e not pictured it but I even smoothed out the underside of the arch where it meets the bumper. I know its not seen but I dont like to leave it half done!



Skirt section inside the rear door all finally smoothed.

Other side is pretty much the same, no need for another pic!




My smooth boot wasnt so smooth! I'd only just noticed, a bit of a sand and minimal filler resulted in 1 actual smooth boot...result.



Engine as it is now. Its not fast but doesnt mean it cant look good! Polished the intake pipe myself, gave it a mega clean ( look at 1st pic in thread to see the state of it) Sprayed black most bits and added green detailing.


How I started out to make the front bumper meet the arches. My old bumper donated these small sections to the cause.







Made a fibreglass bracket to attatch the splitter to the bumper. It was for a cossie but I had to get a bit choppy with the grinder to shape to the mk6 bumper.


Also had fixed in place the tow eye cover and cut a slot for the tow strap.




Possible colour???? I'll test an area later but think blue and black will look the nuts.


Comments or suggestions welcome. Cheers for looking.

Full thread at www.escortevolution.co.uk

 

great update

 

thats not normally my thing but i like the build none the less, cant help thinking it would brilliant as a 3 door track car one some nice wide wheels but what your doing is great, keep the updates coming...


...also... did i spy some neons/led's under the car? I think these could be pulled off on some cars again nowadays and give quite a good look since no one has used them for years.

 

LOL yeah you spied them! Been removed now though. Still lurking in the garage I think. Would be good project for a 3 door, I got the car for free years ago and thought it'd be different from the norm to do this. Plus I couldnt be arsed to pay out for another car when I had one here!

 

Great work there, and it looks good!

 

Inside the rear arches /skirts have now been smoothed. Also gave inside the arches a brush down......Tonnes of crap up there!



Started to wet/dry everything now. Bar the front bumper, all the main fibreglass/filler work is done. Just a few pin holes im uncovering here and there as i smooth it all down.


I seriously HATE wet n dry. It takes aaaaageeeeeeeeeeeees! The paper wears down really quick too so not much rubs down but on the plus side.....I've got arms like popeye!

Just a sneak of the finally decided colour!


Any comments or ideas welcome. cheers, Lee.

Full thread @ www.escortevolution.co.uk

 

good work so far

 

Looking good, keep at it!

 

well done great looking car hope all the hard work pays off cant wait to see it finished

 

fair play bud your doing well

i was one of the original members on escortevo no# 3 after ian and stoo

 

Looking good so far

Brian

 

Its getting there now.

 

Havnt updated for a while so here goes.

A small mishap ended up the rage taking over! Here is the result:


Re-sprayed my morette masks and centre caps.


Whilst cleaning out the morettes I found this!!!!!

Not what you expect to find. They have been sat for a long time and i never noticed when the 1st arrived! Now I have fitted 4 new replacement lamps. Pic to follow later. Another pain in the ass cost to find money for....but you cant have shitty, rusty lights fact. After all, its small things that make big differences.

Stripped and Prepped the mirrors/door handles.



After a colour mix up all my paint stuff arrived.....correct this time


Body panels have now taken up the garden for prepping and paint. The mrs is well happy


Nice collection of stonechips



Using the wheelie bins and garden chairs as benches, all panels bar the rear doors are ready for paint.


All the door shuts have now been rubbed down and etch primer applies where I've hit bare metal. The inside of the boot just needs scuffing up before paint.
Sideskirts need a small amount of final prep which I hope to do tonight when the other half gets home from work. Then ....thats the shell and the boot all ready for spraying.
I have also removed and resprayed the scuttle panel, wiper arms, door triangle's and the mirror base plates matt black. Pics to follow later.

I have couple days off work this week when I'm hoping to spray, however I am a bit apprehensive spraying while its so hot! Any tips from any painters about best time/conditions to spray would be appreciated. Its cellulose I've got with I think a 2 pack laquer. Any idea on flash times? I think 30 mins between coats in this weather is a bit long lol. Also, if its too hot am I at risk of paint blistering on hot bodywork?? Thanks for any help.
Comments/ideas welcome Cheers, Lee.

 

Looks brilliant Lee.

2 packed mine in baking head and three coats of final black with 30 minutes between each coat, not sure how correct this was to do but turned out with mirror finish.

 

Hella impressed with the work that's gone into this. Not my cup of tea at all these days, but it's very impressive.

I also applaud it for being a 5 door. I think if it was a 3 door, then there'd not really be anything different about it; so many 3dr Escorts have had the Cos/wide arch treatment over the years, it's almost a breath of fresh air to see a 5dr having the same/similar treatment. (Not to say it's never been done to a 5dr, but it's less common)

Really like the the engine bay; the green and black works really nice with the small amount of chrome, and the interesting use of RST charge carrier for air intake looks good.

 

This had caught me by surprise when I seem
The thread title I though " oh dear" but no low I take that back, you've got some skills there dude, loving this thread, one to watch.