saff re, re-build.. smooth bay. RS500 style bumper project back on
02-10-2008, 07:36 PM
#1
saff re, re-build.. smooth bay. R.I.P.
thought i'd finally start a resto thread. re built the car about 4 years ago from a bare shell. unfortunatlly after 6000 miles one of the long studs broke, meaning the engine had to come apart again. here are a few pics from the original build to give an idear what the car was like before it came apart again
then the wheels painted white
the cossy was used on my wedding day to take the wife to church
and now on to the current re-build
the offending stud
3 gueses where the rest of the stud was. luckly a mate of mine is a prescition engeneer & was able to remove the broken part pretty easly after the engine was stripped
whilst the engine is out i've decided to smooth the engine bay & slam panel
then the wheels painted white
the cossy was used on my wedding day to take the wife to church
and now on to the current re-build
the offending stud
3 gueses where the rest of the stud was. luckly a mate of mine is a prescition engeneer & was able to remove the broken part pretty easly after the engine was stripped
whilst the engine is out i've decided to smooth the engine bay & slam panel
Last edited by jaimesdna; 08-11-2016 at 11:47 AM.
how clean is that; love it on the white rims
02-10-2008, 07:50 PM
#4
a light skim of filler to see how thing are going
the curve of this side of the slam panel is different to the passanger side so i made a template of the curve. cut slits into a piece of angle to bend it to the correct curve then welded it into shape
taked into place
welded in & ground down
another skim of filler
shoud hopefully be able to rub down the filler tomorrow to see how much more work needs doing
Very nice indeed though m8. 
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05-10-2008, 01:16 PM
#24
PassionFord Post Troll
that looks real nice i like it.
what springs do you have on the back? what does it drive llike bein that low? have you got shims on the back? and one more question lol, where did you get the fuel pump cradle? cheers mate. good luck with the rebuild
what springs do you have on the back? what does it drive llike bein that low? have you got shims on the back? and one more question lol, where did you get the fuel pump cradle? cheers mate. good luck with the rebuild
05-10-2008, 01:19 PM
#25
they are castle performance springs. handling is ok, im sure it would be much better if it sat a bit higher so that is a bit of a compremise i guess. yes it has got some shims on the rear courtesy of mike r. the fuel pump cradle is just the standard one been powder coated silver
05-10-2008, 02:07 PM
#27
never really liked the tow eye, so off that came. there was also a repair needed to the cross member wher the meta is double skinned & water had got in. all the rot was cut out & replaced with 2mm steel
this leaves the problem of no tow eye. so thanks to my mate tony a new one was made. the actual tow eye was from his old fiat bravo. he then drilled & tapped a piece of round bar to screw it into & cut some strenghting plated to weld round it. then weld them to the cross member. i was gonna fit this to the middle of the crossmember but i'm now thing it will probably just cause it to bend, it will probably be welded to one side
the bottom end is now back together with the help from tony
all the old parts were checked & re used as they had only done 6000 miles. the compression was lowered & valve cut outs were done by harvey gibbs courtesy of mike r
also new high quality long studs were purchased from mike r, so hopefully wont be having any problems with these
after a long time searching for a good head with lots of life left in it i finally founf this on ebay for Ł650. its fully ported & has double valve springs. it was check by harvey through mike r & found to be a good head.
as the engine is long studded it causes problems doing up the nuts as you cant get a 18mm socket in the holes. so there are two choices, machine down a socket or machine the holes bigger. as i thought id probably just end up loosing the socket i guesse it'd be a better option to machine the head. this was done by another mate of mine who is a precition engeneer. he is the same person that machined the broken studs out of the block.
these are some of the other parts i have brought
alloy air box lid to fit a t4 inlet pipe. Ł70 off ebay. i'm really happy with it. the quality is excelent
verniers from jasesapphy
.
i also got some brembo 8 pot calipers from an amg merc. these really are huge
i will get some audi rs4 356mm disks to go with these when i have spare cash
i mocked up some disks just to make sure they fit behing the wheels
this leaves the problem of no tow eye. so thanks to my mate tony a new one was made. the actual tow eye was from his old fiat bravo. he then drilled & tapped a piece of round bar to screw it into & cut some strenghting plated to weld round it. then weld them to the cross member. i was gonna fit this to the middle of the crossmember but i'm now thing it will probably just cause it to bend, it will probably be welded to one side
the bottom end is now back together with the help from tony
all the old parts were checked & re used as they had only done 6000 miles. the compression was lowered & valve cut outs were done by harvey gibbs courtesy of mike r
also new high quality long studs were purchased from mike r, so hopefully wont be having any problems with these
after a long time searching for a good head with lots of life left in it i finally founf this on ebay for Ł650. its fully ported & has double valve springs. it was check by harvey through mike r & found to be a good head.
as the engine is long studded it causes problems doing up the nuts as you cant get a 18mm socket in the holes. so there are two choices, machine down a socket or machine the holes bigger. as i thought id probably just end up loosing the socket i guesse it'd be a better option to machine the head. this was done by another mate of mine who is a precition engeneer. he is the same person that machined the broken studs out of the block.
these are some of the other parts i have brought
alloy air box lid to fit a t4 inlet pipe. Ł70 off ebay. i'm really happy with it. the quality is excelent
verniers from jasesapphy
.i also got some brembo 8 pot calipers from an amg merc. these really are huge
i will get some audi rs4 356mm disks to go with these when i have spare cash
i mocked up some disks just to make sure they fit behing the wheels
05-10-2008, 02:26 PM
#28
after a long time searching i finally found a small turbo plenum chamber. these thing are like rocking horse shit to find & normally cost a fortune. i got this from a passion ford member (cant remember who) for Ł150 delivered. i'll probably get the hole for the air charges sensor welded up & moved to the middle. then get it powder coated the same as the old one
22-02-2009, 05:01 PM
#37
update time. its been cold so i've been avoiding going out int the garage unitill i got a heater. after looking i found this on ebay
so im now running out of excuces to not not go out there
i sold the amg calipers as it was gonna cost a fortune to get disks bell etc.
so with a big thanx to NUTS RuS i got these. 350mm disks & brembo 4 pot calipers. the calipers will be painted white to match the car
the tow eye is now welded in with strengthining plates
oil cooler brackets are welded in althout im not gonna be running the oil cooler at the moment
ive brought some aero catches to hold the front bumper on
i had to make some drop brackets to mount them but i'll add some pics of them later
finally today i got the bay in primer, dusted with black & ready to rub down
so im now running out of excuces to not not go out there
i sold the amg calipers as it was gonna cost a fortune to get disks bell etc.
so with a big thanx to NUTS RuS i got these. 350mm disks & brembo 4 pot calipers. the calipers will be painted white to match the car
the tow eye is now welded in with strengthining plates
oil cooler brackets are welded in althout im not gonna be running the oil cooler at the moment
ive brought some aero catches to hold the front bumper on
i had to make some drop brackets to mount them but i'll add some pics of them later
finally today i got the bay in primer, dusted with black & ready to rub down
