German Escort MK3 Cosworth 4x4 - street legal - little photoshooting
20-07-2008, 07:55 PM
#201
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No really news at this point... This and last weekend I spent my time in taking off the undercoat and paint where I will weld both parts together. I didn't took any pics of that... I mean, everybody knows how it looks like 
It takes more time then I first thought... I will ask next weekend 2 friends to help me so that I can finally start with welding... I can't wait anymore to start with that 
Would be a big progress....
The next days I will think about which way of welding I will do: TIG or MAG
I will make some tries with some sheets of metal...
What are you guys thinking? What do you recommend? TIG? MAG?
Cheers
Cyril
It takes more time then I first thought... I will ask next weekend 2 friends to help me so that I can finally start with welding... I can't wait anymore to start with that Would be a big progress....The next days I will think about which way of welding I will do: TIG or MAG
I will make some tries with some sheets of metal...
What are you guys thinking? What do you recommend? TIG? MAG?
Cheers
Cyril
Last edited by Cyril Sneer; 20-07-2008 at 08:07 PM.
30-07-2008, 09:23 PM
#203
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mig welding, i would have thought stick welding would have been to tricky for what you want to do, what u welding just normal mild steel?
different if you welding stainless or alloy
different if you welding stainless or alloy
31-07-2008, 07:35 AM
#205
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Thanx CozzyKing
Hehe... Also spent last weekend just in cleaning and cutting the sheets. But I'm nearly done... It really pisses me of that I loose so much time in that... but it must be done...
Actually I decided not to USE MAG or TIG... Instead of that I will weld most of the sheets by spot-welding... I just bought the machine on Ebay. It's an old one, but still works and is enough for my needs...
With that it is far cleaner, no grinding, much faster and it is better regarding stability.
Sure there will be some places which can't be reached with that, but then I can still MAG or TIG weld them... We will see...
So that's the progress for now... Wenny...
Hehe... Also spent last weekend just in cleaning and cutting the sheets. But I'm nearly done... It really pisses me of that I loose so much time in that... but it must be done...
Actually I decided not to USE MAG or TIG... Instead of that I will weld most of the sheets by spot-welding... I just bought the machine on Ebay. It's an old one, but still works and is enough for my needs...
With that it is far cleaner, no grinding, much faster and it is better regarding stability.
Sure there will be some places which can't be reached with that, but then I can still MAG or TIG weld them... We will see...
So that's the progress for now... Wenny...
04-08-2008, 10:12 AM
#206
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Thread Starter
Ready for welding!!!
After weeks of grinding, everything is done. I think without the help of my friends, I would spend 3 more weeks doing that shit. Thanx Nils, Klaus and Stefan! Also for the support!
In order to reach most of the sheets for welding, I raised the shell of the jig by 10cm. That gives me enough space so should be quite easy.
The shell ist now fixed onto the jig... Nothing can move... Next weekend I will make some tries before I start with the real welding session... maybe Sunday?? It would be a big progress!!!
Here some pics...
After weeks of grinding, everything is done. I think without the help of my friends, I would spend 3 more weeks doing that shit. Thanx Nils, Klaus and Stefan! Also for the support!
In order to reach most of the sheets for welding, I raised the shell of the jig by 10cm. That gives me enough space so should be quite easy.
The shell ist now fixed onto the jig... Nothing can move... Next weekend I will make some tries before I start with the real welding session... maybe Sunday?? It would be a big progress!!!
Here some pics...
08-08-2008, 09:54 PM
#209
Too many posts.. I need a life!!
Cyril - I take my hat of to you - well done Sir,
Never considered other conversions of this type might not be that 'straight', but looking at the amount of effort and thought you've put in clearly shows how difficult it is to mate a Sierra floor pan with a MK3 Escort shell - Where are your 'bearings' so to speak unless you build a jig like you've so cleverly done!!
Keep going mate --- Hope I don't see a live axle in there as well.... that's what always put me off the Gatrac G3 cars...
Top project
Never considered other conversions of this type might not be that 'straight', but looking at the amount of effort and thought you've put in clearly shows how difficult it is to mate a Sierra floor pan with a MK3 Escort shell - Where are your 'bearings' so to speak unless you build a jig like you've so cleverly done!!
Keep going mate
--- Hope I don't see a live axle in there as well.... that's what always put me off the Gatrac G3 cars... Top project
11-08-2008, 09:33 AM
#210
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Thread Starter
Thanx alot mate...
Before I could start to spotweld the shell, I have to build up a cooling system for the electrodes... I know, my "cooling system" looks weird and strange... but it works hehe...
just take a water tank, a radiator of a RS2000, a fuelpump, some tubes and cables... and there it is ... *lol*
Looks like special weapon for Terminator... hehe
And then... let's start the session... With the spotwelding machine, it is so easy and so fast to weld... in 2 hours we have done for about 70% of all points... incredible...
pics tell more then words:
Before I could start to spotweld the shell, I have to build up a cooling system for the electrodes... I know, my "cooling system" looks weird and strange... but it works
hehe...just take a water tank, a radiator of a RS2000, a fuelpump, some tubes and cables... and there it is ... *lol*
Looks like special weapon for Terminator... hehe
And then... let's start the session... With the spotwelding machine, it is so easy and so fast to weld... in 2 hours we have done for about 70% of all points... incredible...
pics tell more then words:
11-08-2008, 07:52 PM
#215
Regular Contributor
very cool project & doing a proper job of it aswell, any pics of where the sierra floor meets the escort inner sills???? & where the escort/sierra inner wings meet??
14-08-2008, 08:32 PM
#216
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Thread Starter
Thanx alot guys... It's a pleasure to hear that you like the project
@rosie: I hope you understand that I'm not going to post too many details. I spent lots of months in preparing this project and everybody should make it's own thoughts how to convert their car...
It's a pleasure to hear that you like the project @rosie: I hope you understand that I'm not going to post too many details. I spent lots of months in preparing this project and everybody should make it's own thoughts how to convert their car...
18-08-2008, 08:21 PM
#222
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i must agree with cozzy king but im looking cos im converting my series one rs to cossie power & looking for advice & a few pointers but agreed a great project!
20-08-2008, 07:59 AM
#225
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same to me 
I first thought to respray it at this original terracota colour, but right now I think I wont do it. But I am still a fan of anthracite grey... So that's the way for now...
The one and only advice I can tell is that you measure as good as possible, and then to re-measure it... I spent most of the time in measuring out both shells...
It also depends on how you convert it... Is it going to be 2WD or 4WD, do you take a Sierra floor, if so: just the front part or the whole floor?
Ah, yes, one more advice: when you start cutting, don't cut out big pieces... Just small ones... one by one... try to find the point where both shells overlap the best. At mine, I have about 98% overlapping metall. I have just 2 or 3 little holes where I have to weld in a sheet.
Be sure: the MK3/MK4 ist not easy to convert, so take your time in preparing the conversion...
Cheers
Cyril
Just one question though are you gona leave the car that lovely terracota colour and have it looking like a standard escort?
i must agree with cozzy king but im looking cos im converting my series one rs to cossie power & looking for advice & a few pointers but agreed a great project!
It also depends on how you convert it... Is it going to be 2WD or 4WD, do you take a Sierra floor, if so: just the front part or the whole floor?
Ah, yes, one more advice: when you start cutting, don't cut out big pieces... Just small ones... one by one... try to find the point where both shells overlap the best. At mine, I have about 98% overlapping metall. I have just 2 or 3 little holes where I have to weld in a sheet.
Be sure: the MK3/MK4 ist not easy to convert, so take your time in preparing the conversion...
Cheers
Cyril
Last edited by Cyril Sneer; 20-08-2008 at 09:03 AM.
20-08-2008, 04:27 PM
#226
20-08-2008, 08:24 PM
#227
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The one and only advice I can tell is that you measure as good as possible, and then to re-measure it... I spent most of the time in measuring out both shells...
It also depends on how you convert it... Is it going to be 2WD or 4WD, do you take a Sierra floor, if so: just the front part or the whole floor?
Ah, yes, one more advice: when you start cutting, don't cut out big pieces... Just small ones... one by one... try to find the point where both shells overlap the best. At mine, I have about 98% overlapping metall. I have just 2 or 3 little holes where I have to weld in a sheet.
Be sure: the MK3/MK4 ist not easy to convert, so take your time in preparing the conversion...
Cheers
Cyril[/QUOTE]
i was thinking of going 4x4 2wd is a bit scary for me i think ive got my series one down to a compleat shell just got to get the donor car & i can make a start on it!
It also depends on how you convert it... Is it going to be 2WD or 4WD, do you take a Sierra floor, if so: just the front part or the whole floor?
Ah, yes, one more advice: when you start cutting, don't cut out big pieces... Just small ones... one by one... try to find the point where both shells overlap the best. At mine, I have about 98% overlapping metall. I have just 2 or 3 little holes where I have to weld in a sheet.
Be sure: the MK3/MK4 ist not easy to convert, so take your time in preparing the conversion...
Cheers
Cyril[/QUOTE]
i was thinking of going 4x4 2wd is a bit scary for me i think ive got my series one down to a compleat shell just got to get the donor car & i can make a start on it!
25-08-2008, 05:07 PM
#229
Wahay!! I've lost my Virginity!!
hi,
been a bit of a voyuer as i dont post much but ive been checking the thread now and then since the start.
ive got a mk3 ive had for 14years and im very interested in this conversion as it is clearly being done to a high standard, especially like the spot welding/forklift.
will you be doing any seam-welding to add extra rigidity/strength to the shell?
(for the record i believe the spot-welds would be enough but for regular track days ect perhaps a bit more? just a suggestion)
anyway very glad to see its starting to come together
all the best,
cris
been a bit of a voyuer as i dont post much but ive been checking the thread now and then since the start.
ive got a mk3 ive had for 14years and im very interested in this conversion as it is clearly being done to a high standard, especially like the spot welding/forklift.
will you be doing any seam-welding to add extra rigidity/strength to the shell?
(for the record i believe the spot-welds would be enough but for regular track days ect perhaps a bit more? just a suggestion)
anyway very glad to see its starting to come together
all the best,
cris
25-08-2008, 06:30 PM
#230
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Thread Starter
Thanx cris... thanx wenny...
No, I dont need to do seam welding... It is easy to explain... in a factory made shell, the spots have e.g. 4 or 5 cm of space between... But I do all 2,5cm a spot... this comes to the same...
We made a test before starting to spot weld... and the spots are perfectly... It is not going to be a track car... It will be for the streets and I will not have so much power... I think I will stop at 350 horsepower... maximum...
Few pics of last weekend...
No, I dont need to do seam welding... It is easy to explain... in a factory made shell, the spots have e.g. 4 or 5 cm of space between... But I do all 2,5cm a spot... this comes to the same...
We made a test before starting to spot weld... and the spots are perfectly... It is not going to be a track car... It will be for the streets and I will not have so much power... I think I will stop at 350 horsepower... maximum...
Few pics of last weekend...
25-08-2008, 07:02 PM
#231
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just looked at them pics & relised you wont have the exhaust melting the brake master cylinder like we do in the right hand drive cars but it looks like you have the loom coming through on the exhaust side
will you be useing the 4x4 exhaust manifold or 2wd manifold ???
the 4x4 manifold leaves more room on that side of the engine but is more restrictive than the 4x4 one
will you be useing the 4x4 exhaust manifold or 2wd manifold ???
the 4x4 manifold leaves more room on that side of the engine but is more restrictive than the 4x4 one
25-08-2008, 09:14 PM
#232
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I will use the 4x4 manifold...
regarding the loom, could be that I am going to wire up a complete new one with fusebox inside of the car...
regarding the loom, could be that I am going to wire up a complete new one with fusebox inside of the car...
25-08-2008, 09:45 PM
#234
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25-08-2008, 10:03 PM
#236
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Yeah blacky... during the week I have alot of time to think about all the small things...
Sometimes I have nightmares *rofl*
But after each weekend when I worked on the car, it often ended with little problems and during the week I try to find solutions so that I can go ahead the following weekend... till now it works no major problems right now...
Sometimes I have nightmares *rofl*
But after each weekend when I worked on the car, it often ended with little problems and during the week I try to find solutions so that I can go ahead the following weekend... till now it works
no major problems right now...
25-08-2008, 10:07 PM
#237
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ye i no what you mean i dread wenny going on Holiday i get loads of texts about new things he wants to do lol every time we get one of his cars nearly finished it gets pulled to bits to get more things done
im sure we will get it finished one day
im sure we will get it finished one day
02-09-2008, 11:51 AM
#238
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big progess during the last few days... wednesday evening, 5 of my mates spontaneously came to my workshop in order to help me... Till 2 o'clock in the night we grinded and welded and did alot of work. So at this point I would like to thank Nils, Klaus, Jens, Marcel and Stefan for their help!!!! You're the best!!!
Last weekend we finished the inside of the shell and put some coat on it. the front is nearly finished... I just have to put on the front panel, the wings will be screwed.
So next update soon to come
Last weekend we finished the inside of the shell and put some coat on it. the front is nearly finished... I just have to put on the front panel, the wings will be screwed.
So next update soon to come
Last edited by Cyril Sneer; 02-09-2008 at 11:53 AM.
