Dan_RS500

Ok thought I'd stop pissing about and get a thread up. Now I know it's a Ka (which to many is a joke to start with) and it's only got a 1300 engine, toy town brakes, blah blah blah, plans are in place to man it up just need to get the cash together!

Ok so here's the story (or you can skip to the pics)... German built and registered, Left hand drive, imported to UK early on in it's life. Owned by one German lady petrol head (she replaced this with a Mustang), purchaced from her by a good mate to get used to a left hand drive for an up coming rally. After that was used as a run about then given to me. The first thing we done to it was completely strip it out and bang in some Recaros from a Series 1 Escort (I think, I took them out of a Sierra so who knows). My original plan was just to thrash it on the local club events while working on some thing for next year, so I didnt really want to spend much on it hence some of the ghetto mods you will see!



Seen it needed tyres anyway and not wantin to spend on wheels too, I went for 185s on the 13 inch steelies.



Had fun throwing her about on the local race track. Done half of the Autotest season, really enjoying it and holding my own against Cossie engined MK2s and Racing Pumas etc. Something started to set in though, it was becoming more than just a quick fling, I wanted this to be my project. I set about looking into more power, zetec seems the cheaper more straight forward way so sourced an Escort to rip the engine out of:



Told it was an 1800, but saw its a 1600. No loss though better than the 1.3! And got 4 vgc 15" alloys with nearly new tyres in the deal too, all for £25! Started working on the engine, stripped and cleaned the head, all was going well but wasn't convinced it was the best thing to do. Needed to get a few things sorted on the car before the engine gets changed so....

This is how it starts, the green has to go. Need to get it sorted for the second half of autotest season which starts first saturday of october.



The seats we fitted were just welded direct to the floor, seemed like a good idea at the time. First up I ripped the driver's seat out so I could get at the floor. Not too bad really, just needs 2 patches on this side and a bit of sill attention.





Ground back and zinc coated


Exploding discs!


The door kept getting in the way so I got it out of the way


Not really happy with the finish, Im blaming the gasless mig. Need to get stuff done in a time limit though so I can always come back to this at a later date.


Then I ran out of welding wire! So I moved onto removing spot wleded brackets for the likes of rear seats etc, while I was working on the c pillar area I noticed a plastic bag full of foam stuffed in there! Only way to get it out was to keep picking at it with some long nosed pliers like a bird's beak! What a mess!



My plan is to get what I can done between events then do a major strip down over the winter break. Hopefully get the zetec in then too, although I have plans for so much more.
This month I'd like to:
Fit side mount seat brackets + fabricate mounts from inner sill to tunnel
Fit bonnet pins and boot lid springs
Remove inner skin on boot lid
Make and fit foot well plates
Make door card for passenger side
Fit wheel spacers + axle spacers
Upgrade brakes
Fit brake bias valve
Make vertical hand brake lever
Respray inside and out (need to come up with a colour scheme)
Maybe get some styling bits like mirrors, spoiler, roof scoop etc.
Maybe get shocks ordered if I have enough money left

Well if you are still with me this far thank you for reading and hope you like the story so far. Its a pretty lame build for this forum I know but I plan to make up for it soon enough!

Comments welcome and please suggestions for a quick ratle can respray!

zetec-Sam

iTrader: (2)

Spray it fluro orange! lol

Red16

Good stuff... keep the photos coming

Dan_RS500

Have thought about the ST electric orange and green! Colour wise Im after that rally slag look. Thinking white shell with blue bumpers and arches, mirrors, spoiler, scoop etc.
Thanks Red!

andy escos

iTrader: (1)

i am glad you started a thread dan it may be just a ka but you can make them into very good fast little cars & one in particular bloody bonkers (400hp cossy in it )its already sitting well with bigger boots on so keep plugging away & keep the updates coming ,good work so far

Dan_RS500

Thanks Andy! Richie's Ka is the main one that made me think about modding my one. With the rear cradle (as it was when I first read about it), the MK6 dash, and the longitudinal mounted YB. I have a similar idea, but I may be restricted with the bulkhead modification ruling for MSA events, need to do more home work.

Tomorrow (or today now) I will get more welding wire and hopefully some materials for the seat mounts etc so maybe an update tomorrow night.

Pob

I like budget builds. Keep updating

alistairolsen

As above, love these sort of builds, looking forward to more!

Dan_RS500

Thanks for your support guys.

Not got much of an update so far, other than the fact the lad down the motor factors is going to get violated by a stilson if he still hasnt got my welding wire tomorrow. I have been doing bits and bobs though, might get some pics tonight and put them up.

Need colour scheme ideas! Im liking the idea of painting the body all one colour then the bumpers, arches, mirrors, spoiler etc a different colour. But what colours would you suggest? Not too fussed if it turns out naff, I can spray it again before the next event

gjh

This looks like an interesting thread, good luck with it.

alistairolsen

I quite like the green, but if youre using it for autotesting then an easy to match flat colour would be best :P

White with anthracite bumpers etc?

Dan_RS500

Thanks

Yeah solid 2 pack, slap it all over the repairs, job done Im after something a bit more mad, my concern with a black or grey for the bumpers is it will just look like the original plastic bumpers. White body with ford blue bumpers etc is winning just now, but it's not very original.

Dan_RS500

Got some bits done over the last couple of nights... Basically stripped every thing off the shell for the respray and removed the dash. Did a bit of chopping of unneeded wiring and plastics, crap like that. Got the dash to one side for some modifications and will probably paint it matt black or try out one of those DIY flocking kits.

Also on the subject of the dash I removed the black plastic frame from the grey outer dash and refitted it to the car, then I will mount the dash using self tappers so now I can quickly and easily remove the it to get to wiring etc. Need to mount the fuse box some where too, in the centre console area would have been nice but not enough slack on the loom

Other than that just been getting it ready for the respray, on to the pics!








Nice pile of plastics to prep and paint.


Drink problem?

Hopefully get the welding done tomorrow and start on the paint prep

Hope you like, let me know what you think

my-first-rst

white shell with blue(like the ford badge) bumpers etc?

Dan_RS500

Yeah thats what I was thinking but its not very original, although it would look very rally slag, big ford vinyl on the quaters and massive blue mud flaps

Small update... got most of the inside painted satin black. Still no welding wire, found another supplier on the island so might have it tomorrow. Started prepping the outside then ran out of wet'n'dry. Need to get stuff ordered too, going to be an expensive weekend I think

Dan_RS500

A mate suggested doing this so I can get a better idea of what colours I want to go with. Some have been done before, some were just for a laugh. I have chosen my top 3 but I'd like to hear what you lot think first please Just tell me exactly what you think when you look at them, tell me your top 3 or maybe theres only one for you. Feel free to suggest ones that arent on there too

andy escos

iTrader: (1)

1st
all black
2nd
magnum grey
3rd
green

Richie.

iTrader: (5)

Here goes ....

1. Moondust Silver

2. Frozen white

3. Ultimate Green

Dan_RS500

thanks guys. Hey Andy Magnum Grey is a great idea, isnt that some Mercedes colour? Anyway who cares, never seen it done on a Ka before (especially not one with a YB) so think I might go for that, excellent!

zetec-Sam

iTrader: (2)

Blue with orange bumpers etc. or orange with blue bumpers etc.

Dan_RS500

There ya go. I actually quite like the orange with blue bumpers. Electric Orange and Imperial Blue hmmm.

alistairolsen

Any of the single colours, or white with anthracite bumpers :P

jonny s2

iTrader: (12)

cool project!
leave it that colour

m4tt274

iTrader: (2)

spray it whatever colour you want...

Chopshop85

iTrader: (4)

Any colour other than a coded ford colour. come on now, lets be different.

crazydan

renember ive got them bits at my house if u need them
i will run up and see it one day :L been saying i will for long enough

Dan_RS500

I'm keen to do it different colours for the rally slag look, the exterior isnt going to stay standard.

Thanks! You really think its a nice colour? I really dont like it lol.

Yes well said, both of you. Trouble is I dont know what I want.

Oh dont you worry, when the Zetec conversion gets going I will need all them bits and your input mate

I have pics and update this evening/ tonight some time.

zetec-Sam

iTrader: (2)

DO IT!

crazydan

oh how did i know that was comeing

kevboy6

lemans green

danme1987

ST orange! all over!

Dan_RS500

Well some progress over the weekend... Prepped up the shell for paint, sorted any rust spots although its pretty mint as it had a respray about 3 years ago. Rubbed the whole thing down by hand, 400 dry. Then on with the primer. Didnt get any pics but Im sure you can picture a Ka in primer!

Then I turned my attention to the doors and tail gate. These Ka doors are flippin heavy! So out with the grinder! (sorry dont have a before pic)



Not having a panel stand or even a proper trestle I had to make do with a kiddies home work desk I stole







While all this primer was drying I had to make a decission on colour. And it has been decided.












Satin Black

I gave the door and tail gate shuts a quick dry rub then coloured them with satin black being sure to flick some on to the outer panels for a good fade in when I spray the out side.



And then the same to the inside of the door.



Once dried fitted the door back on so it dont get damaged and tucked it away in the corner all wrapped up again.



Just got to do the other door and the tail gate then spray the whole out side of the car

Been thinking about wheel colour now, they are the Escort Devil ones
white
black
leave them silver?

Also got some Cossie Latice wheels away for refurb they would look hard in satin black too.

Comments please

Dan_RS500

Concidered both but not really what Im after. Want some thing with more agro to it, the Ka is too smiley as it is! Thanks for your in put

Dan_RS500

Ok time for an up date! Well I didnt make my October deadline, I decided not to. I have been doing a lot of thinking, reading, measuring. To cut a long story short my initial plan was to get the shell decent with decent suspension and brakes etc and chuck in a Zetec. Then gradually up grade the engine and power etc but I dont want to be stuck with front wheel drive. The idea then was to fit mondeo/rs2000 4x4. Turns out the transfer boxes cant take much torque so no point using it so that plan stopped there.

I have stripped the car completely bar the wind screen.
I started on the chassis modifications: removed the front panel, slam panel and bumper bar. Chassis legs boxed off.
Started working underneath, stripping underseal and seam sealer etc, decided I need a rollover jig so got some steel and made one.
































Not much to show for all these weeks but in one way or another I have been very ocupied by it, there has been a lot of behind the scenes work reading up on things and research etc. Hopefully the next update will have something decent to show.

Bodge22

Nice one mate, I'm loving all these Ka threads popping up. TBH I haven't been on here in a while, so wouldn't have seen em anyway!!

I should start a thread of my own really! As I am doing my own little Ka project, but i'm to lazy to keep it up to date

crazydan

nice progress dan ill pop down this week

Dan_RS500

What's the spec of your's? Is it that one in your sig? (I have about 4 billion more questions depending on your answers!) Thanks for the support, you should definately do a thread it is a bit of a pain some times with all the photobucket codes stuff but Im sure there are pleanty on here who will apreciate the effort

Push bike? You welcome round any time mate, PS bring a grinder

Bodge22

Yes it is the one in my sig mate, don't hit me with all 4 billion questions at once

Spec...

MK1 Focus RS engine (FWD)

Shot peened IB5 box, Quaife diff and lengthened final drive

Fully welded cage custom made by Owen Engineering

FRS Brembo front callipers and disks/Standard FRS rear setup with hubs.

And a shed load of other stuff that i can't think of at 2 o'clock in the morning

I'll see about getting a thread knocked up tomorrow and i'll put a full spec list on there.

Dan_RS500

Excellent, I'll have a look at your thread and then come back to the questions

crazydan

yeah push bike
wont be long till its back on the road though

i was gonna ask which grinder bt 9" will do

ran out of welding wire again?