erst estate going 4wd,now on the road
06-07-2009, 10:16 PM
#164
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got a bit more done today and theres definately no going back now lol i decided it would be easier to cut out the whole floor from beneath where the rear seat goes so i drilled all the spot welds out,then removed the floor from the chassis then cut the chassis out
the rear of the sill were rusty so cut them out both sides and replaced them with some 1/8 inch thick metal which will strengthen the area a bit
also welded a plate onto the floor where it goes vertical to the base of the seat,this will also strengthen the area aswell,i had to cut into the plate slightly so i could get an angle in the metal to match the shape of the floor
had a few holes from where i drilled the spot welds out holding the chassis so plug welded those aswell
got a few more plates to weld in tomorrow and should have the sierra chassis welded in place late tomorrow afternoon
the rear of the sill were rusty so cut them out both sides and replaced them with some 1/8 inch thick metal which will strengthen the area a bit
also welded a plate onto the floor where it goes vertical to the base of the seat,this will also strengthen the area aswell,i had to cut into the plate slightly so i could get an angle in the metal to match the shape of the floor
had a few holes from where i drilled the spot welds out holding the chassis so plug welded those aswell
got a few more plates to weld in tomorrow and should have the sierra chassis welded in place late tomorrow afternoon
07-07-2009, 10:38 PM
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got a bit more done today,got the strengthening plate welded in on the other side and the holes plug welded up
i then got 2 more plates welded in 1 on each side,these are the main pieces that will be holding the weight of the front beam mounts once they are welded into the floor a bit more
i then got the sierra chassis bolted to the diff and beam and then jacked it up into place roughly
tomorrow i will measure up everything then get it all in place and can then start welding the chassis into place
i then got 2 more plates welded in 1 on each side,these are the main pieces that will be holding the weight of the front beam mounts once they are welded into the floor a bit more
i then got the sierra chassis bolted to the diff and beam and then jacked it up into place roughly
tomorrow i will measure up everything then get it all in place and can then start welding the chassis into place
10-07-2009, 02:39 PM
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just having a break at the moment so thought i would update a little,i got the chassis measured and lined up then tacked in place,started to weld it and i ran out of gas for the welder,managed to get some today after no luck yesterday and have started the welding now properly,will get a few pics up later after ive got a bit more done
10-07-2009, 09:19 PM
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heres a few pics of what i got done today,finished welding part of the rear shock mounts,just got to make some filler plates for where i cut the original shock mounts out
as the sierra chassis sits a bit higher than the escort chassis i made up some plates to join the 2
ended up like this
so i got some cardboard and held it underneath and took a template for each side then welded them in place aswell
once that was done i started welding the floor in again that goes under the rear seat
i just need to trim it up a bit more then can weld a new plate in for the floor and trim it to suit then,will hopefully have a lot more done over the weekend
as the sierra chassis sits a bit higher than the escort chassis i made up some plates to join the 2
ended up like this
so i got some cardboard and held it underneath and took a template for each side then welded them in place aswell
once that was done i started welding the floor in again that goes under the rear seat
i just need to trim it up a bit more then can weld a new plate in for the floor and trim it to suit then,will hopefully have a lot more done over the weekend
keep going looks like a lot of progress 
13-07-2009, 09:40 AM
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got a bit more done over the weekend but ran out of welding wire so not as much as i would have liked,got the car on a tilter so i could get welding underneath
had to box off the chassis to the floor,started like this
then ended like this,just got to do the other side when i get the tilter swapped round
started welding in a sheet of metal for the floor,its not the neatest but its not going to be seen
i will hopefully have the rear finished tuesday at the latest
had to box off the chassis to the floor,started like this
then ended like this,just got to do the other side when i get the tilter swapped round
started welding in a sheet of metal for the floor,its not the neatest but its not going to be seen
i will hopefully have the rear finished tuesday at the latest
13-07-2009, 06:52 PM
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Looking good, how was the underside of the car? much of the dreaded rust or surprisingly good? also what areas you planning on beefing up?
13-07-2009, 07:00 PM
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the underside of the estate is actually very good for its age,the only bits of rot are the back ends of the sills which i will be boxing off anyway to clear the rear suspension and the battery tray needs doing and the rear bottom edge of the rear 1\4s behind the bumper and thats all,all the new sections that im welding in are being seam welded so should be strong enough anyway
13-07-2009, 07:10 PM
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also got a small amount done today but have run out of gas again lol also havnt got any cutting discs for the grinder,i just need to make up some templates for all the blanking plates then when i get the cutting discs i will get them cut out and welded in,i reckon i need another 4 hours with everything that i need and the backend will be finished
13-07-2009, 07:33 PM
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Sounding good, I seriously want to come back to the ford fold after selling my s2, currently have an s4 but not sure i'll enjoy that. Trying to decide between either a rs turbo or cosworth sapphire rep with zetec turbo. Biggest thing thats putting me off currently is with the audi's I have had no problems with rust etc.
Still miss both my estates (had one mk3 and 1 mrk4) both of which suffered seriously from rust.
Still miss both my estates (had one mk3 and 1 mrk4) both of which suffered seriously from rust.
13-07-2009, 07:57 PM
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ive got another mk4 estate that i use everyday and its a bit of a dog really will probably only last another couple years before it gets to much to repair for the mot,the good thing with this estate though is that im only the 3rd owner on it,the girl i bought it from only owned it a year and ive owned it about 5 years now so that helps to how clean it is plus when i got it it only had 66000 miles on the clock aswell
17-07-2009, 09:38 PM
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this has come to a halt for a few days as im having trouble getting hold of a bottle of gas for the welder,im hoping to have something sorted tomorrow so i can get going on it again as ford fair is getting close now lol
17-07-2009, 10:00 PM
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i just want it into a rolling shell for ford fair,the rear will only take a few hours once i get gas sorted for the welder as ive got all the blanking plates i need made up and ready to weld in,then i just need to get the tunnel and front end sorted then lol
20-07-2009, 07:00 PM
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the underside of the estate is actually very good for its age,the only bits of rot are the back ends of the sills which i will be boxing off anyway to clear the rear suspension and the battery tray needs doing and the rear bottom edge of the rear 1\4s behind the bumper and thats all,all the new sections that im welding in are being seam welded so should be strong enough anyway
21-07-2009, 07:03 PM
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what are you doing for a petrol tank?i kno your a long way of from it but just looking through the resto & wondered if you thought of it?