Moonstone 3-door
#1
Wahay!! I've lost my Virginity!!
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A Big hello to everyone
and heres my car which is a 1986 moonstone blue sierra cosworth
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Cos6.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Cos9.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Cos8.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/James05080700611.jpg)
Specs of the car are its running with the sapphire 4X4 engine and running gear, stage 3 tuned at 330bhp (though ive personally not had it on rolling road yet), RS500 cut out in front bumper, Genuine RS500 front splitter and lower boot spoiler, delocked boot and doors, escort cossie alloys on gaz coilovers so it sits better and little bits of shiney stuff under the bonnet
Bought to enjoy and take to shows the plan soon changed when after a couple of months of ownership I noticed a crack running along the inner wings of the car and around the suspension turrets which turned into this![Sad](https://passionford.com/forum/images/smilies/icon_sad.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Cos5.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car3.jpg)
After finding all the grot under the bonnet decision was made to go to town and bring the car back up to standard by replacing the inner and outer front wings for genuine bits and so the engine bay was stripped ready for the removal of the engine and gearbox
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car7.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car4.jpg)
After few days the car was ready have engine dropped so my mate arrived in his pulling machine (not the sort that attarcts the ladies) and the car was taken to a unit with ramp to have the engine dropped straight out the bottom
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car8.jpg)
As is the way come the next day couldnt get into unit as keys had been lost. Unaware of this I turned up the following day to have shock of my life when I saw the car looking like
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car10.jpg)
Not a recommended idea using a fork lift for this but as needs must the brake and fuel lines were disconnected, engine mounts undone and fingers crossed as the car was lifted in the air and car and engine parted company
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car12.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car11.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car13.jpg)
Once high enough the engine was wheeled out from underneath and the car loaded up and taken to mates where work commenced on those wings, next update will be just that
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Cos6.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Cos9.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Cos8.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/James05080700611.jpg)
Specs of the car are its running with the sapphire 4X4 engine and running gear, stage 3 tuned at 330bhp (though ive personally not had it on rolling road yet), RS500 cut out in front bumper, Genuine RS500 front splitter and lower boot spoiler, delocked boot and doors, escort cossie alloys on gaz coilovers so it sits better and little bits of shiney stuff under the bonnet
Bought to enjoy and take to shows the plan soon changed when after a couple of months of ownership I noticed a crack running along the inner wings of the car and around the suspension turrets which turned into this
![Sad](https://passionford.com/forum/images/smilies/icon_sad.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Cos5.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car3.jpg)
After finding all the grot under the bonnet decision was made to go to town and bring the car back up to standard by replacing the inner and outer front wings for genuine bits and so the engine bay was stripped ready for the removal of the engine and gearbox
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car7.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car4.jpg)
After few days the car was ready have engine dropped so my mate arrived in his pulling machine (not the sort that attarcts the ladies) and the car was taken to a unit with ramp to have the engine dropped straight out the bottom
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car8.jpg)
As is the way come the next day couldnt get into unit as keys had been lost. Unaware of this I turned up the following day to have shock of my life when I saw the car looking like
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car10.jpg)
Not a recommended idea using a fork lift for this but as needs must the brake and fuel lines were disconnected, engine mounts undone and fingers crossed as the car was lifted in the air and car and engine parted company
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car12.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car11.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car13.jpg)
Once high enough the engine was wheeled out from underneath and the car loaded up and taken to mates where work commenced on those wings, next update will be just that
![Big Grin](https://passionford.com/forum/images/smilies/icon_biggrin.gif)
Last edited by Jay's 3-door; 18-01-2011 at 05:02 PM.
#3
Wahay!! I've lost my Virginity!!
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So engine removed and car back at mates work began on those inner wings. Due to the state they where in I wanted to replace the whole lot, however I had no idea at this point how hard the inners were to get hold of
in the end after thinking we'd have to work with what was there got a call from geoff at chorley street garage who had a sierra in he only wanted roof off for his, great
this was snapped up and the whole lot brought back
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car14.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car15.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car16.jpg)
Can see a lot better than what was there, having been able to source 2 new outer wings work set about to remove the inners. The outer wings were ground off to access the inner wings then a lot of spot drilling of the welds were required to get the inners off with minimal damage
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car17.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car18.jpg)
Eventually after a lot of drilling/prying/swearing both wings where safely off and ready for use![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
![Rolling Eyes](https://passionford.com/forum/images/smilies/icon_rolleyes.gif)
![Big Grin](https://passionford.com/forum/images/smilies/icon_biggrin.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car14.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car15.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car16.jpg)
Can see a lot better than what was there, having been able to source 2 new outer wings work set about to remove the inners. The outer wings were ground off to access the inner wings then a lot of spot drilling of the welds were required to get the inners off with minimal damage
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car17.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car18.jpg)
Eventually after a lot of drilling/prying/swearing both wings where safely off and ready for use
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car19.jpg)
#4
Wahay!! I've lost my Virginity!!
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Cheers Harris, luckily its bit down the line now, been meaning to join up for a while so just going through the pictures now get up to speed. At the time was kick in teeth for sure but weve had worse down the line as you'll see
![Wink](https://passionford.com/forum/images/smilies/icon_wink.gif)
#5
Wahay!! I've lost my Virginity!!
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So wings ready to go could concentrate on getting front end of the car sorted. Car was brought back to mates and put on railway sleepers to keep the car level while work was going on
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car31.jpg)
The dashboard was removed along with 20 odd years of wiring and add on's
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car22.jpg)
With all wiring out of the way could have a proper look under the bonnet and be sure nothing was going to be accidentley cut in the process, had a bit more banging and poking around the front end of the car to see how bad things where and.....
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car24.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car25.jpg)
On the face of it the nearside doesnt look to bad, amazing what a bit of bog can do though
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car26.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car27.jpg)
So both sides gone as bad as they where just as well I pulled the car off the road when I did, and refused temptation of a lap around silverstone at ford fair 2 weeks previous due to engine problems![Wink](https://passionford.com/forum/images/smilies/icon_wink.gif)
Next step was getting the lot out of there, Car had been bogged and failed to stop the rot so if a jobs worth doing its worth doing properly. And where any cossie's concerned this has to be the case so outer wings where removed and cleaned up to find the spot welds
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car32.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car33.jpg)
Can see how bad now the inner wings where. a bit of this was now carefully cut out to give better access to the spot welds, now you see it
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car34.jpg)
and now you dont
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car35.jpg)
this gone any spot welds where cleaned up with a wire brush along the chassis leg and body of the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car36.jpg)
Until again we where able to pry the remaining piece off and expose the chassis leg
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car38.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car39.jpg)
this process was repeated for the near side until the front end of the car was looking just a bit bare
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car42.jpg)
Next updates the refitting of the wings
its fag break now though all this typing isnt good
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car31.jpg)
The dashboard was removed along with 20 odd years of wiring and add on's
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car22.jpg)
With all wiring out of the way could have a proper look under the bonnet and be sure nothing was going to be accidentley cut in the process, had a bit more banging and poking around the front end of the car to see how bad things where and.....
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car24.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car25.jpg)
On the face of it the nearside doesnt look to bad, amazing what a bit of bog can do though
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car26.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car27.jpg)
So both sides gone as bad as they where just as well I pulled the car off the road when I did, and refused temptation of a lap around silverstone at ford fair 2 weeks previous due to engine problems
![Wink](https://passionford.com/forum/images/smilies/icon_wink.gif)
Next step was getting the lot out of there, Car had been bogged and failed to stop the rot so if a jobs worth doing its worth doing properly. And where any cossie's concerned this has to be the case so outer wings where removed and cleaned up to find the spot welds
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car32.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car33.jpg)
Can see how bad now the inner wings where. a bit of this was now carefully cut out to give better access to the spot welds, now you see it
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car34.jpg)
and now you dont
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car35.jpg)
this gone any spot welds where cleaned up with a wire brush along the chassis leg and body of the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car36.jpg)
Until again we where able to pry the remaining piece off and expose the chassis leg
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car38.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car39.jpg)
this process was repeated for the near side until the front end of the car was looking just a bit bare
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car42.jpg)
Next updates the refitting of the wings
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
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#8
Wahay!! I've lost my Virginity!!
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![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
I was looking for a black one at first but glad I opted for a moonstone, like you say I dont think theres a better colour especially in fading light as the blue starts popping more. The cars coming along nice, been bit of a mission from how it started out but the lights at the end of the tunnel, more pics and updates on the way
![Wink](https://passionford.com/forum/images/smilies/icon_wink.gif)
Last edited by Jay's 3-door; 11-04-2010 at 05:57 PM. Reason: because i cant spell
#12
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Will follow this, Makes me worry that the fronts that bad though, whats it like underneath?
Do you think youre going to be chasing rust for a while, You certainly seem to have the commitment to get it done.
I would have given up after about half one of them wings.
Forget how old these cars are getting now
Do you think youre going to be chasing rust for a while, You certainly seem to have the commitment to get it done.
I would have given up after about half one of them wings.
Forget how old these cars are getting now
Last edited by Ebonycossie4x4; 11-04-2010 at 06:20 PM.
#13
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So following day got on with trial fitting the wings to make sure everything lined up right, cue excitment as we offered the new wings into place
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car44.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car43.jpg)
Looking good and already miles better than what was there, before welding the wings back on though the jacking points of the car where now exposed after the removal of the wings, over the 20 odd years of cars life these have been flattened and crushed so while accessable these were knocked back down
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car62.jpg)
The wings where then cleaned then lined up and my mate (being a better welder than me) set about welding them back onto the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car50.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car56.jpg)
The spot weld which had been drilled out where filled back in and a long time later the inner wings where back on the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car57.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car58.jpg)
The bonnet had been left on throughout this process and so the outer wings where placed and clamped on and the bonnet shut to check everything was still lining up as it should, and im delighted to say everything did, better than expected really for 2 people with no experience in this
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car54.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car55.jpg)
At the front where the headlights sit again for the life of me couldnt find the 2 required pieces, thought id hit gold on an internet site only to be told the parts where now obsolete. Luckily being an engineer I have some experience in sheet metal work so went about making a paper template from the old part, transferred that to cardboard then traced the shape onto a piece of sheet metal
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car64.jpg)
This was then bent and shaped to match and welded onto the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car66.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car65.jpg)
as last job with the inner wings all the little holes where filled with weld and the bigger ones had pieces made and welded in to give a clean base for after spraying and get rid of some of the holes which were not being used, a dust of copper spray was applied to protect the wings from going to rusty while the car was outside under a sheet
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car73.jpg)
With that cue the cheesy grin and thinking the worse of its over now at least, how those words came back to haunt me the following week
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car44.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car43.jpg)
Looking good and already miles better than what was there, before welding the wings back on though the jacking points of the car where now exposed after the removal of the wings, over the 20 odd years of cars life these have been flattened and crushed so while accessable these were knocked back down
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car62.jpg)
The wings where then cleaned then lined up and my mate (being a better welder than me) set about welding them back onto the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car50.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car56.jpg)
The spot weld which had been drilled out where filled back in and a long time later the inner wings where back on the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car57.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car58.jpg)
The bonnet had been left on throughout this process and so the outer wings where placed and clamped on and the bonnet shut to check everything was still lining up as it should, and im delighted to say everything did, better than expected really for 2 people with no experience in this
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car54.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car55.jpg)
At the front where the headlights sit again for the life of me couldnt find the 2 required pieces, thought id hit gold on an internet site only to be told the parts where now obsolete. Luckily being an engineer I have some experience in sheet metal work so went about making a paper template from the old part, transferred that to cardboard then traced the shape onto a piece of sheet metal
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car64.jpg)
This was then bent and shaped to match and welded onto the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car66.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car65.jpg)
as last job with the inner wings all the little holes where filled with weld and the bigger ones had pieces made and welded in to give a clean base for after spraying and get rid of some of the holes which were not being used, a dust of copper spray was applied to protect the wings from going to rusty while the car was outside under a sheet
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car73.jpg)
With that cue the cheesy grin and thinking the worse of its over now at least, how those words came back to haunt me the following week
![Surprised](https://passionford.com/forum/images/smilies/bigcry.gif)
#14
Wahay!! I've lost my Virginity!!
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![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
Again sir thanks for the welcome and comments, been to a few ford fairs and think its certainly the best family car wise to be a part of
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
Will follow this, Makes me worry that the fronts that bad though, whats it like underneath?
Do you think youre going to be chasing rust for a while, You certainly seem to have the commitment to get it done.
I would have given up after about half one of them wings.
Forget how old these cars are getting now
Do you think youre going to be chasing rust for a while, You certainly seem to have the commitment to get it done.
I would have given up after about half one of them wings.
Forget how old these cars are getting now
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
![Wink](https://passionford.com/forum/images/smilies/icon_wink.gif)
Last edited by Jay's 3-door; 11-04-2010 at 06:39 PM.
#16
Wahay!! I've lost my Virginity!!
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So next day with weather taking a turn for the worse we decided while the car was looking like it did would make no sense to not give the rest of it a proper check over and make sure the rust hadnt spread, on the face of it the rest of the car didnt look to bad but on the safe side the rear subframe and petrol tank where removed for a closer inspection
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car75.jpg)
And heres me looking slightly worried under the car where the subframe mounts
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car74.jpg)
At this point decided best way to go about things was to invest in a jig to rotate the car and get better access and viewing of the underneath, a quick call to rick at Mk2Mania and the following week was in possession of a jig which the car was put on ready for the next stage
![](http://i187.photobucket.com/albums/x206/mk2mania/cars%20on%20mk2mania%20jigs/DSCF0410.jpg)
![](http://i187.photobucket.com/albums/x206/mk2mania/cars%20on%20mk2mania%20jigs/DSCF0402.jpg)
A bargin at Ł200 if only for the ease of not having to crawl on back, his website details are here if anyones looking at buying a jig for their project
![](http://i187.photobucket.com/albums/x206/mk2mania/cars%20on%20mk2mania%20jigs/DSCF0403.jpg)
with car now on its side could see to what extent the rust had spread and it didnt make for a good picture![Sad](https://passionford.com/forum/images/smilies/icon_sad.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car80.jpg)
Could see straight away where the subframe mounts was rotten and it had already been patched up further along. cue of s**t. with that hot air gun was plugged in and began heating up the underbosy sealant to make it easier to scrape off, unfortanatly it was actually the underbody sealant holding the chassis leg together so the more I scraped the worse the situation got![Sad](https://passionford.com/forum/images/smilies/icon_sad.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car83.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car85.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car86.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car89.jpg)
So not good when the whole subframe locates on a pin thats floating in midair
but in finding this at least decision to buy the jig had been justified. It was at this point I was ready for throwing the towel in until a chance look on ebay brought me across one of the members here selling a complete genuine ford chassis leg, not quite believing my luck for a change this was quickly snapped up and was on way to me. few days wait and next part was started removing the old chassis leg
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car75.jpg)
And heres me looking slightly worried under the car where the subframe mounts
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car74.jpg)
At this point decided best way to go about things was to invest in a jig to rotate the car and get better access and viewing of the underneath, a quick call to rick at Mk2Mania and the following week was in possession of a jig which the car was put on ready for the next stage
![](http://i187.photobucket.com/albums/x206/mk2mania/cars%20on%20mk2mania%20jigs/DSCF0410.jpg)
![](http://i187.photobucket.com/albums/x206/mk2mania/cars%20on%20mk2mania%20jigs/DSCF0402.jpg)
A bargin at Ł200 if only for the ease of not having to crawl on back, his website details are here if anyones looking at buying a jig for their project
![](http://i187.photobucket.com/albums/x206/mk2mania/cars%20on%20mk2mania%20jigs/DSCF0403.jpg)
with car now on its side could see to what extent the rust had spread and it didnt make for a good picture
![Sad](https://passionford.com/forum/images/smilies/icon_sad.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car80.jpg)
Could see straight away where the subframe mounts was rotten and it had already been patched up further along. cue of s**t. with that hot air gun was plugged in and began heating up the underbosy sealant to make it easier to scrape off, unfortanatly it was actually the underbody sealant holding the chassis leg together so the more I scraped the worse the situation got
![Sad](https://passionford.com/forum/images/smilies/icon_sad.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car83.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car85.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car86.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car89.jpg)
So not good when the whole subframe locates on a pin thats floating in midair
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#19
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Just read the whole thread and pics, what a nightmare!!!!!!
Full credit to you tho mate, and I really hope all goes well with the repair, at least you will have a solid car when done.
Good luck and will keep watching the rebuild
Full credit to you tho mate, and I really hope all goes well with the repair, at least you will have a solid car when done.
Good luck and will keep watching the rebuild
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While waiting for the chassis leg to arrive scraping continued with the rest of the car, the other rear chassis leg was scraped back and though not brilliant was in a lot better condition than the other side
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car97.jpg)
eventually the whole car was scraped of sealant and could look at what was lurking underneath
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car96.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car100.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car101.jpg)
so more bits of rust
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car90.jpg)
more bits flattened by quick fit fitters
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car102.jpg)
and more bits we'll cover as we go along
by the time this point had been reached chassis leg was here and work began on removing the old one. As the full section was being replaced and the car was currently located on the jig via the chassis leg the car was blocked up on wood to hold its weight while the leg was removed
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car111.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car112.jpg)
Once any rock in the car had gone set about like the front wings wire brushing along the chassis leg to find the spot welds which where then marked up clearly
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car105.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car106.jpg)
where possiable the centres where punched to help the spot weld drill locate and each spot weld was then drilled out
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car107.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car114.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car115.jpg)
where access proved difficult sections of the leg where removed to make things a bit easier
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car117.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car116.jpg)
eventually after a fair bit of messing around and banging the leg was removed from the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car118.jpg)
and again because nobody can resist th new piece was put roughly into place to make sure it would fit directly on
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car120.jpg)
It did and so the next part was welding the new leg onto the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car97.jpg)
eventually the whole car was scraped of sealant and could look at what was lurking underneath
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car96.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car100.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car101.jpg)
so more bits of rust
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car90.jpg)
more bits flattened by quick fit fitters
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car102.jpg)
and more bits we'll cover as we go along
![Wink](https://passionford.com/forum/images/smilies/icon_wink.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car111.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car112.jpg)
Once any rock in the car had gone set about like the front wings wire brushing along the chassis leg to find the spot welds which where then marked up clearly
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car105.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car106.jpg)
where possiable the centres where punched to help the spot weld drill locate and each spot weld was then drilled out
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car107.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car114.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car115.jpg)
where access proved difficult sections of the leg where removed to make things a bit easier
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car117.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car116.jpg)
eventually after a fair bit of messing around and banging the leg was removed from the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car118.jpg)
and again because nobody can resist th new piece was put roughly into place to make sure it would fit directly on
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car120.jpg)
It did and so the next part was welding the new leg onto the car
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And so moving onto the fitting of the new leg and first things first the side which meets the sill behind the chassis leg was looking a little worse for wear as you can see here
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car122.jpg)
This piece was cut out and removed to eliminate any chance of the rust returning and a new piece cut and welded in to replace it
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car123.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car124.jpg)
With this in out came the angle grinder and the area where the chassis leg locates was cleaned up and deburred
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car126.jpg)
The chassis leg was then drilled for welding in the same way the inner wings where attached, then measurments taken off the subframe to get the distance across and the existing leg on the other side for position
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car128.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car129.jpg)
The leg was then held in place using the seat belt bolt and other nuts and bolts to pull the leg tight to the cars body
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car130.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car131.jpg)
then one by one all the holes where filled with weld and the leg was seam welded in other places for added strength as this is something I dont want to take a risk with
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car134.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car132.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car133.jpg)
and with that another big tick and another big headache was crossed off the list, next up the cars sills
oh yes it goes on, lol
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car122.jpg)
This piece was cut out and removed to eliminate any chance of the rust returning and a new piece cut and welded in to replace it
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car123.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car124.jpg)
With this in out came the angle grinder and the area where the chassis leg locates was cleaned up and deburred
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car126.jpg)
The chassis leg was then drilled for welding in the same way the inner wings where attached, then measurments taken off the subframe to get the distance across and the existing leg on the other side for position
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car128.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car129.jpg)
The leg was then held in place using the seat belt bolt and other nuts and bolts to pull the leg tight to the cars body
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car130.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car131.jpg)
then one by one all the holes where filled with weld and the leg was seam welded in other places for added strength as this is something I dont want to take a risk with
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car134.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car132.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car133.jpg)
and with that another big tick and another big headache was crossed off the list, next up the cars sills
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Cheers for the welcome and comments dooge, looks like a nice moonstone 3dr you have as well there, actually in one piece unlike mine, lol
I thankyou again sir for the kind comments, it wasnt meant to be a project initially, and as I found the rust I certainly used words worse than project to sum her up, but when it became one the theory is do it right and make it last rather than do it again in a few years time
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Last edited by Jay's 3-door; 11-04-2010 at 09:31 PM.
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so chassis leg ticked off the list moved onto the sill on the same side, with being able to get hold of sills quite easily and being another spot prone to rust had decided ages ago I was going to replace them, plus somebody had already done a bit of welding to them which was visable without the bodykit which was bad enough anyway as you can see from this picture
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car135.jpg)
The new sill was placed on and marked out
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car137.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car138.jpg)
This was then cut out all the way along so the full piece could be used
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car139.jpg)
after getting the sill off became obvious the car had some work to the floor in the past, the sill was floating in mid air and the lip of which we needed to weld the replacement sill to was none existent
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car142.jpg)
a piece of angle inch x inch angle was bought from auto crash parts and welded into place
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car143.jpg)
after this strips from another length where cut and welded on to reattach the inner sill to the car body
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car144.jpg)
Before refitting the outer sill the inner sills were wire brushed down and given a coat of POR-15 rust preventative paint to help protect them in the future
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car141.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car145.jpg)
Once dry the sill was put into position and carfully welded into place to avoid distorting the rear quarter panel
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car147.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car150.jpg)
the sill now on finishing jobs where to grind the weld flat and cut the plate at the back to match the size of the sill
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car152.jpg)
and looking underneath was slowly starting to make headway at last on the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car154.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car155.jpg)
Next up was taking the wooden supports out and flipping the car around the other way to repeat the work on opposite side
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car135.jpg)
The new sill was placed on and marked out
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car137.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car138.jpg)
This was then cut out all the way along so the full piece could be used
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car139.jpg)
after getting the sill off became obvious the car had some work to the floor in the past, the sill was floating in mid air and the lip of which we needed to weld the replacement sill to was none existent
![](http://i333.photobucket.com/albums/m377/J220_cosworth/Car142.jpg)
a piece of angle inch x inch angle was bought from auto crash parts and welded into place
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car143.jpg)
after this strips from another length where cut and welded on to reattach the inner sill to the car body
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car144.jpg)
Before refitting the outer sill the inner sills were wire brushed down and given a coat of POR-15 rust preventative paint to help protect them in the future
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car141.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car145.jpg)
Once dry the sill was put into position and carfully welded into place to avoid distorting the rear quarter panel
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car147.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car150.jpg)
the sill now on finishing jobs where to grind the weld flat and cut the plate at the back to match the size of the sill
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car152.jpg)
and looking underneath was slowly starting to make headway at last on the car
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car154.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car155.jpg)
Next up was taking the wooden supports out and flipping the car around the other way to repeat the work on opposite side
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So car now back under strain of jig was brought around level so the inside of the sill where the door is could be shaped correct with the weld
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car157.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car158.jpg)
the whole process was repeated on the drivers side, out with the old
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car180.jpg)
In with the new
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car184.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car183.jpg)
little bits of rot where then removed from various points on the car and replaced, so a bit on the drivers rear wheel arch
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car185.jpg)
a piece was cut out at the back on the drivers side and replaced
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car186.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car187.jpg)
new pieces where made for the rear wheel arces near the sills
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car161.jpg)
bit of work on the wheel arch
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car162.jpg)
more work at the back of the car where there was rust
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car178.jpg)
and a slightly bigger plate a bit further along to sort it out where someone had botched the car up in their wisdom
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car177.jpg)
With most of the welding now complete moved onto wire brushing the floor back to bare metal making sure there was nothing that had been missed, update to follow of the next process
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car157.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car158.jpg)
the whole process was repeated on the drivers side, out with the old
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car180.jpg)
In with the new
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car184.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car183.jpg)
little bits of rot where then removed from various points on the car and replaced, so a bit on the drivers rear wheel arch
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car185.jpg)
a piece was cut out at the back on the drivers side and replaced
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car186.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car187.jpg)
new pieces where made for the rear wheel arces near the sills
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car161.jpg)
bit of work on the wheel arch
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car162.jpg)
more work at the back of the car where there was rust
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car178.jpg)
and a slightly bigger plate a bit further along to sort it out where someone had botched the car up in their wisdom
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car177.jpg)
With most of the welding now complete moved onto wire brushing the floor back to bare metal making sure there was nothing that had been missed, update to follow of the next process
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Most loborious job of the lot this one and was done over the course of a few weeks, after first few nites raised question of why i was doing it but paint i was going to use needed to bond to bare metal, so over first few nights got the front section done with
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car166.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car167.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car168.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car169.jpg)
Turned the car back over and at this point had to make decision on other chassis leg. Had held off for as long as could do hoping one would turn up but as a few people have found if and when they do there not about for long. As this side wasnt as bad we went about repairing the section, so here it is from an earlier post as reminder (the cars also the other way around on jig at this point)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car189.jpg)
Not as bad as the other side but still a concern, therefore as much was removed as possiable. the chassis leg here is double skinned and so 2 pieces of sheet metal (thicker than original) were cut and shapped, the first piece was welded in place and ground back
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car190.jpg)
then the second piece was welded over the top and edges rounded off to match what was there in the first place
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car191.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car192.jpg)
That done I could carry on brushing the back end of the car so by the time thats was done the difference was 100x times better than what was there
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car193.jpg)
as one last bit of welding for the underside the crumpled jacking points further under the car (again think those garages that flatten your floor, of which if you look at the floor now on this weve knocked it out again
) were now letting it down badly, had tried jack hammer and not got anywhere but ripping the metal rather than pulling it, rather than leaving them crumpled welded a new piece over the top, so again from an earlier picture heres how they looked and how they ended up
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car198.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car196.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car197.jpg)
again a marked improvement, I dont think its going to be a concourse car because as I said i like driving it to much but I would like to know having the chance to do something about it that it was done![Big Grin](https://passionford.com/forum/images/smilies/icon_biggrin.gif)
So heres a picture of the car bare metaled underneath
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car200.jpg)
thats a lot better than when I began posting this afternoon, In that picture its just drying off after being degreased and that leads me onto the final post before were at where the car is at the moment thankgod
I really should of joined sooner, lol
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car166.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car167.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car168.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car169.jpg)
Turned the car back over and at this point had to make decision on other chassis leg. Had held off for as long as could do hoping one would turn up but as a few people have found if and when they do there not about for long. As this side wasnt as bad we went about repairing the section, so here it is from an earlier post as reminder (the cars also the other way around on jig at this point)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car189.jpg)
Not as bad as the other side but still a concern, therefore as much was removed as possiable. the chassis leg here is double skinned and so 2 pieces of sheet metal (thicker than original) were cut and shapped, the first piece was welded in place and ground back
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car190.jpg)
then the second piece was welded over the top and edges rounded off to match what was there in the first place
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car191.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car192.jpg)
That done I could carry on brushing the back end of the car so by the time thats was done the difference was 100x times better than what was there
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car193.jpg)
as one last bit of welding for the underside the crumpled jacking points further under the car (again think those garages that flatten your floor, of which if you look at the floor now on this weve knocked it out again
![Wink](https://passionford.com/forum/images/smilies/icon_wink.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car198.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car196.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car197.jpg)
again a marked improvement, I dont think its going to be a concourse car because as I said i like driving it to much but I would like to know having the chance to do something about it that it was done
![Big Grin](https://passionford.com/forum/images/smilies/icon_biggrin.gif)
So heres a picture of the car bare metaled underneath
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car200.jpg)
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
Last edited by Jay's 3-door; 13-04-2010 at 12:32 AM.
#37
PassionFord Post Whore!!
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#40
Wahay!! I've lost my Virginity!!
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Join Date: Apr 2010
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Im hoping this is my last progress update of the night now, with the car bare metaled I began process of applying POR-15 to the underside. For those who dont know of it its a rust preventative paint so I thought if any car needs it its got to be this one ![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
step one, use POR-15 marine clean and degrease the car, dont use normal degreaser on any rust paint, few of mates have found out to cost most degreasers cause the paint to react, wash off after half an hour and leave car to dry
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car200.jpg)
Step two, use metal ready which leaves a zinc coat over the metal, dissolves any bits of surface rust and gives the paint something to bite into, can see it as blue liquid pooling in corner of this pic
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car202.jpg)
step three, get the paint brushed on and hope it does exactly what it says on the tin![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car203.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car204.jpg)
sills, rear windows, rear arches and petrol cap recess got the same treatment
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car209.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car205.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car210.jpg)
that done the remainder of the front was wire brushed and painted in the same way
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car221.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car215.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car220.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car222.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car226.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car227.jpg)
this was done on the inside of the car as well along the floor
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car228.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car234.jpg)
a before and after here
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car235.jpg)
the inside quarter panels were sprayed in eastwoods rust encapsulator then covered in grey schultz for sound proofing
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car229.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car231.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car232.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car233.jpg)
And im pleased say that thats where the car currentley is at the moment, If you've read full thread then cheers for sticking with it
be less from now on as can update as go along though its not far off going to be sprayed. Again thanks all for looking and comments tonight, appreciate them all
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
step one, use POR-15 marine clean and degrease the car, dont use normal degreaser on any rust paint, few of mates have found out to cost most degreasers cause the paint to react, wash off after half an hour and leave car to dry
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car200.jpg)
Step two, use metal ready which leaves a zinc coat over the metal, dissolves any bits of surface rust and gives the paint something to bite into, can see it as blue liquid pooling in corner of this pic
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car202.jpg)
step three, get the paint brushed on and hope it does exactly what it says on the tin
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car203.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car204.jpg)
sills, rear windows, rear arches and petrol cap recess got the same treatment
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car209.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car205.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car210.jpg)
that done the remainder of the front was wire brushed and painted in the same way
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car221.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car215.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car220.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car222.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car226.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car227.jpg)
this was done on the inside of the car as well along the floor
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car228.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car234.jpg)
a before and after here
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car235.jpg)
the inside quarter panels were sprayed in eastwoods rust encapsulator then covered in grey schultz for sound proofing
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car229.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car231.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car232.jpg)
![](http://i333.photobucket.com/albums/m377/J220_cosworth/car233.jpg)
And im pleased say that thats where the car currentley is at the moment, If you've read full thread then cheers for sticking with it
![Big Grin](https://passionford.com/forum/images/smilies/icon_mrgreen.gif)
![](https://passionford.com/forum/images/smilies/smile012.gif)