S1 resto, Winter Engine Rebuild/New Wheels
13-02-2008, 09:09 PM
#1
It Wasnt Me!
Thread Starter
S1 resto, Winter Engine Rebuild/New Wheels
I hate that word 'restoration' sounds like too much hard work! :doh:
Stuck this thread up for Rab's benefit seeing as he's too lazy to look on the S1 forum!
Well to start I was planning on taking the car off the road at the end of january as the scuttle panel has had it and the battery tray wasnt looking too good, fearing the worst the A pillar was gubbed too!
But as fate would have it, I had an ignition wiring problem that oddly appeared) so I took it off the road on the 15th of january to begin the fixing process early.
First of all I needed to strip the engine bay around the bulkhead/pass inner wing area and the front end so the rott can be cut out and replaced with new panels, and as I'll likely just paint the front of the car after the works been done, perfectly good wings will be sacraficed because of the scuttle panel having to come off but c'est la vie as they say in France
Now for some pics when I started:
Most of the engine bay done for now.
Reason im doing this:
picked away at it so looks worse than it did, also the big chip on the door recently appeared, shows how much it must of been moving tho I do remember hitting a large pot hole before it appeared....d'oh!
Some pics of the interior after jus removing dash:
Wiring, oh the joys:
shadey connector blocks on ignition wires, no wonder it had a problem...cowboy's
carpet back for a swatch expecting the worst:
Pass side, hard to tell how bad it is, gonna wire grind it back with a drill and see what's left altho doesnt feel soft or holed..sills are still solid on inside!
Drivers side:
Bulkhead from inside view...shady repair done previously, why o why do people do these things if they cant do it right :doh:
Fuse box area from underside:
Glad one bits not rotten lol
Will see what else needs done once wings are off.
Well thats it for now, i've got more pics from tonight of the rest of the interior removed, never found any more rott so the rest of the inside is solid, underside is solid also still in that grey/blue primer albeit under loads of oil :dance:
Will upload them pics tomorow night tho.
Plan for now is:
get it welded wherever it needs it, paint what bits have been welded (dont think i'll repaint the full car as the rest of the paint is good as it had a full respray a few years ago. Then fit my new rebuilt gearbox
clutch and release bearing maybe a new steering rack/track rod ends and rebuild the steering columm with a repair kit and drive it as I really miss it already!!! Idea is not to do too much at once, main thing is the bodywork, the rest can be done anytime.
Thoughts/future plans are:
possibly fit ECU system, Omex ideally but very expensive even if I do the loom myself, megasquirt looks good but not sure how good it is!
fit some modded track rod ends so steering arms sit in the correct position for a lowered car
paint the underside in white/paint suspension etc
fit new shocks and springs
Adj track control arms
MEF style compression struts
tubular manifold
cosworth brakes all round
Also, hopefully once the rest is mint, build a 2.1 zvh, but that's a long way off unfortunately and im sure i'll be mega skint by then!
Sorry for all the writing as I know no ones interested in this crap just the pics
promise i'll not type as much after my first post 
Stuck this thread up for Rab's benefit seeing as he's too lazy to look on the S1 forum!
Well to start I was planning on taking the car off the road at the end of january as the scuttle panel has had it and the battery tray wasnt looking too good, fearing the worst the A pillar was gubbed too!
But as fate would have it, I had an ignition wiring problem that oddly appeared) so I took it off the road on the 15th of january to begin the fixing process early.
First of all I needed to strip the engine bay around the bulkhead/pass inner wing area and the front end so the rott can be cut out and replaced with new panels, and as I'll likely just paint the front of the car after the works been done, perfectly good wings will be sacraficed because of the scuttle panel having to come off but c'est la vie as they say in France
Now for some pics when I started:
Most of the engine bay done for now.
Reason im doing this:
picked away at it so looks worse than it did, also the big chip on the door recently appeared, shows how much it must of been moving tho I do remember hitting a large pot hole before it appeared....d'oh!
Some pics of the interior after jus removing dash:
Wiring, oh the joys:
shadey connector blocks on ignition wires, no wonder it had a problem...cowboy's
carpet back for a swatch expecting the worst:
Pass side, hard to tell how bad it is, gonna wire grind it back with a drill and see what's left altho doesnt feel soft or holed..sills are still solid on inside!
Drivers side:
Bulkhead from inside view...shady repair done previously, why o why do people do these things if they cant do it right :doh:
Fuse box area from underside:
Glad one bits not rotten lol
Will see what else needs done once wings are off.
Well thats it for now, i've got more pics from tonight of the rest of the interior removed, never found any more rott so the rest of the inside is solid, underside is solid also still in that grey/blue primer albeit under loads of oil :dance:
Will upload them pics tomorow night tho.
Plan for now is:
get it welded wherever it needs it, paint what bits have been welded (dont think i'll repaint the full car as the rest of the paint is good as it had a full respray a few years ago. Then fit my new rebuilt gearbox
clutch and release bearing maybe a new steering rack/track rod ends and rebuild the steering columm with a repair kit and drive it as I really miss it already!!! Idea is not to do too much at once, main thing is the bodywork, the rest can be done anytime.Thoughts/future plans are:
possibly fit ECU system, Omex ideally but very expensive even if I do the loom myself, megasquirt looks good but not sure how good it is!
fit some modded track rod ends so steering arms sit in the correct position for a lowered car
paint the underside in white/paint suspension etc
fit new shocks and springs
Adj track control arms
MEF style compression struts
tubular manifold
cosworth brakes all round
Also, hopefully once the rest is mint, build a 2.1 zvh, but that's a long way off unfortunately and im sure i'll be mega skint by then!
Sorry for all the writing as I know no ones interested in this crap just the pics
promise i'll not type as much after my first post
Last edited by vroooom ptssssh; 08-11-2010 at 10:27 PM.
13-02-2008, 09:11 PM
#2
It Wasnt Me!
Thread Starter
Heres the rest of the pics (all 4 of them) and how it sits at the moment as promised:
Pass side looks allot worse than it is I hope, all because it was leaking water through the hole at the scuttle panel, as u can see the drivers side floorpan isnt near as bad, so if the pass side never got wet it wouldnt be as rusty
Rear end is mint...
Found a hole in the inner driver side rear arch about the size of 50p...it's cause the sill at the back to rott, so the driver side sill infront of the rear wheel will need replaced!
New box:
Will be going back down on sunday to get some more off it and grind all the paint off the pass side floor/bulkhead to see whats what! and remove the heater box/matrix.
wish me luck
Pass side looks allot worse than it is I hope, all because it was leaking water through the hole at the scuttle panel, as u can see the drivers side floorpan isnt near as bad, so if the pass side never got wet it wouldnt be as rusty
Rear end is mint...
Found a hole in the inner driver side rear arch about the size of 50p...it's cause the sill at the back to rott, so the driver side sill infront of the rear wheel will need replaced!
New box:
Will be going back down on sunday to get some more off it and grind all the paint off the pass side floor/bulkhead to see whats what! and remove the heater box/matrix.
wish me luck
13-02-2008, 09:11 PM
#3
It Wasnt Me!
Thread Starter
Done a bit more tonight, took the rest of the bodykit off so I could see how bad the drivers side sill was and to check the rest...
Drivers side rear half is soft/holed where the inner wheel arch has holed and let water come through and side inside..
Pass side is mint
pass side floor pan is fubar
Heres how it sits at the mo, it's not bad considering it's only had a small amount of welding previously
Now the decision is, do I do what I originally planned, strip it to a bare shell, do the welding and paint the whole chassis underside included, or do I do a half arsed job and weld what needs welded and paint what needs painted....im swaying more towards the better option now as it's more than half way stripped now!
Ah decisions!
drivers side is good
Drivers side rear half is soft/holed where the inner wheel arch has holed and let water come through and side inside..
Pass side is mint
pass side floor pan is fubar
Heres how it sits at the mo, it's not bad considering it's only had a small amount of welding previously
Now the decision is, do I do what I originally planned, strip it to a bare shell, do the welding and paint the whole chassis underside included, or do I do a half arsed job and weld what needs welded and paint what needs painted....im swaying more towards the better option now as it's more than half way stripped now!
Ah decisions!
drivers side is good
13-02-2008, 09:12 PM
#4
It Wasnt Me!
Thread Starter
Went an done a bit today start to get ready to take the engine out an strip engine bay:
Turbo was pumped, I knew this already tho lol
Metering unit out, and im adiment it's NOT going back in, looks so much better without!!
Other bits off that wont be going back on!
Turbo was pumped, I knew this already tho lol
Metering unit out, and im adiment it's NOT going back in, looks so much better without!!
Other bits off that wont be going back on!
13-02-2008, 09:17 PM
#6
It Wasnt Me!
Thread Starter
Got a bit more done tonight 13/02/08
Brake servo and linkage off, turbo and manifold off to get rad out easier and engine removed easier also.
rear bumper and lights/number plate off
will get pics up later on.
still need to remove fuel tank/pump
brake lines
fuel lines
engine and box
door/window rubbers
door handles and all glass
then it's ready to go for welding and then paint!
Euan, takin an Escort aparts bad enough never mind a sapph, too many more bits for me
Brake servo and linkage off, turbo and manifold off to get rad out easier and engine removed easier also.
rear bumper and lights/number plate off
will get pics up later on.
still need to remove fuel tank/pump
brake lines
fuel lines
engine and box
door/window rubbers
door handles and all glass
then it's ready to go for welding and then paint!
Originally Posted by rapidcossie
you doing mine next dave?
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13-02-2008, 09:27 PM
#9
It Wasnt Me!
Thread Starter
rapidcossie, Yea well no point beating about the bush
Lee Reynolds, Well going by today's S1 standards it's not bad battery tray, fuse box and rear arch were all crap repairs done previous, car would of been solid if they'd of been fixed properly, that's led to sill rotting and pass floorpan...it could be worse I suppose.
Atleast now I'll know it's right and put together properly
Lee Reynolds, Well going by today's S1 standards it's not bad
battery tray, fuse box and rear arch were all crap repairs done previous, car would of been solid if they'd of been fixed properly, that's led to sill rotting and pass floorpan...it could be worse I suppose.Atleast now I'll know it's right and put together properly
13-02-2008, 09:30 PM
#10
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About time Davvy boy. Will be worth the effort when you're finished mate. Get yourself a decent big power engine built. You know it makes sense! 
13-02-2008, 09:41 PM
#11
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you say the metering unit is not going back in, I'm rebuilding my turbo and in need of all the small bits, I'll buy a few bits off ya rather than throw them ..
Keep the pics coming .
I'm rebuilding my turbo and in need of all the small bits, I'll buy a few bits off ya rather than throw them .. Keep the pics coming .
13-02-2008, 10:13 PM
#14
It Wasnt Me!
Thread Starter
DazC, All bits needing welding will get done, underside is getting stripped and stonechipped/painted
I couldnt afford to sandblast/dip the shell if thats what you mean?
But it will get what it needs and hopefully that will be ok!
I couldnt afford to sandblast/dip the shell if thats what you mean?
But it will get what it needs and hopefully that will be ok!
13-02-2008, 10:24 PM
#15
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No need to do the dipping and blasting as long as it gets cleaned up properly back to good metal and the rot is cut away. As long as you get that done it'll be fine.
Mine is needing a little bit of attention again.
Mine is needing a little bit of attention again.
14-02-2008, 05:04 PM
#25
It Wasnt Me!
Thread Starter
DazC, yep will be doing that mate all over! Thats a shame yours needs some attention, but im sure it'll get what it needs 
Cheers for the comments all! dont let me give up half way through, or buy another project
Nothing majour happening with it atm all very boring just now until it comes back from paint I guess...
Got couple more pics of the strip down but phones being a toss
Cheers for the comments all! dont let me give up half way through, or buy another project
Nothing majour happening with it atm all very boring just now until it comes back from paint I guess...
Got couple more pics of the strip down but phones being a toss
15-02-2008, 05:01 PM
#30
It Wasnt Me!
Thread Starter
Originally Posted by Lambchop
fuckin hell dave! good luck with this
thought you were buying a saff tho?
thought you were buying a saff tho?
zetecapri, yea deffo seen allot worse, which is good! lol
cheers every1 else!
19-02-2008, 11:17 PM
#31
Redumbdancy
Just spotted this Davey - great work so far. Im glad you've decided to keep it. It looks in pretty good condition, all things considered. If you need a hand any time, give me a shout.
23-02-2008, 10:43 PM
#32
It Wasnt Me!
Thread Starter
Richard, thanks mate very kind of you to offer! Im sure I could use a hand putting it back together sometime in the future
I went down today, havent been down for over a week as had the flew, and went to Fantazia last weekend so wasnt in any fit state on sunday to do anything! lol
Got the exhaust, fuel tank/pump off and the full wiring loom....dear god what have I done?????
Couple of non exciting pics...
Now it's a case of it going off for welding, all going well that'll happen next weekend but dont hold your breath!
And clean everything up inc wiring, also paint what brackets etc are going back on
rear light gaskets
wiper assembley kit
headlamp brackets
New decals
and all the rest!
I went down today, havent been down for over a week as had the flew, and went to Fantazia last weekend so wasnt in any fit state on sunday to do anything! lol
Got the exhaust, fuel tank/pump off and the full wiring loom....dear god what have I done?????
Couple of non exciting pics...
Now it's a case of it going off for welding, all going well that'll happen next weekend but dont hold your breath!
And clean everything up inc wiring, also paint what brackets etc are going back on
rear light gaskets
wiper assembley kit
headlamp brackets
New decals
and all the rest!
23-03-2008, 04:47 PM
#36
It Wasnt Me!
Thread Starter
About time I updated I think....
Was waiting on panels and looking for someone to weld it, so david (you know the one thats always got a beer in his hand) Kindly offered to help me out Although I think he wishes he never now
Anyway, got all the panels and a new fuel tank
Scuttle panel (thanks Russel smith!!)
Inner wing repair section
2 front wings
drives side full sill
battery tray
Few other bits needing fixed but nothin david cant handle
Got the engine and g/box out the other night and cut off some panels and rott today! (well david did I supervised )
Pics...
Looks no to bad...
Ah bollox it looks worse now
Wings off, scuttle panel off, battery tray cut out and inner wing section cut out..
david assures me it looks worse than it is tho and he can fix it no prob! some man!
Lots more to do over the next wee while, cant wait...
Was waiting on panels and looking for someone to weld it, so david (you know the one thats always got a beer in his hand) Kindly offered to help me out
Although I think he wishes he never now Anyway, got all the panels and a new fuel tank
Scuttle panel (thanks Russel smith!!)
Inner wing repair section
2 front wings
drives side full sill
battery tray
Few other bits needing fixed but nothin david cant handle
Got the engine and g/box out the other night and cut off some panels and rott today! (well david did I supervised
)Pics...
Looks no to bad...
Ah bollox it looks worse now
Wings off, scuttle panel off, battery tray cut out and inner wing section cut out..
david assures me it looks worse than it is tho and he can fix it no prob! some man!
Lots more to do over the next wee while, cant wait...
23-03-2008, 11:14 PM
#40
It Wasnt Me!
Thread Starter
Euan, it does look bad the now but hopefully be back together within a couple of weeks!
but aye your right, some amount of work
Homer, Gonna clean all the metal up, shutz and paint it white (all inner arches and underside) wiring will run through the inner wing so you cant see it in the bay!
no point doing a half job now
but aye your right, some amount of work
Homer, Gonna clean all the metal up, shutz and paint it white (all inner arches and underside) wiring will run through the inner wing so you cant see it in the bay!
no point doing a half job now