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My saff cossie updated (25/4/2020)

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Old 07-01-2019, 09:00 PM
  #1561  
Glenn_
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Just had a look on your thread. Wow it's proper fooked.
Old 15-02-2020, 12:06 PM
  #1562  
Glenn_
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So bit of an update since it been a while. The end of last year 2019 I decided it was time to give the underside a bit of a tidy up. I knew the jacking points were a bit of a mess so I thought I would give it a go and sorting them out. For new panels they were a fortune to buy.

So I bought a complete sierra floor pan which was local to me.

Cheap as chips I cut out the jacking points and sold what I didn't need on,I made a bit of money back too.

So it was onto the jacking points.
Old 15-02-2020, 12:18 PM
  #1563  
Glenn_
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The passenger side.


what a mess

All welded in and stone chipped/undersealed.

Then painted

Now the drivers side.

It was worse than the passenger side.

Old 15-02-2020, 12:22 PM
  #1564  
Glenn_
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Drivers side all done. There not to concours spec but to me there a 10 times better than they were. They wont be getting used to jack the car up again.
Old 15-02-2020, 12:33 PM
  #1565  
Glenn_
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I want to redo the fuel pipes again cause I'm not happy with them so I thought I might as well drop the rear axle out cause it will be easier to do the fuel pipes.


I checked all the rear chassis legs and floor for any rot.

I found a bit in the passenger rear chassis leg.

Chop it out.






Old 15-02-2020, 12:37 PM
  #1566  
Glenn_
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I also found rot round where the rear abs sensor comes into the car.



Old 15-02-2020, 12:44 PM
  #1567  
Glenn_
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So at the moment the rear beam is getting prepped for primer and paint before it goes back in.

Old 15-02-2020, 01:09 PM
  #1568  
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Looking good mate , fronts sat waiting in my back yard now lol
Old 15-02-2020, 03:46 PM
  #1569  
Glenn_
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Ha ha its had more owners when it was chopped up than it has when the car was in one piece.
Old 15-02-2020, 04:38 PM
  #1570  
james kiely
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Nice job glenn
Old 15-02-2020, 05:54 PM
  #1571  
Glenn_
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Yeh it's not bad. Miles better than it was. It's never gonna be concours but I just want it to look right and be right.
Old 15-02-2020, 06:28 PM
  #1572  
studabear
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Good update Glenn. Nice when you can do it yourself.

I'm 24 years in the motor trade and have never done any welding.

Luckily the only welding my old Ford has needed has been for modifications. I got one of the absolute best in the business for that.
Old 16-02-2020, 10:50 AM
  #1573  
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The only thing I cant really do it paint body panels.

Welding is easy it just takes a bit of practice. Some welds might look messy but as long as it's got good penetration you can soon grind it down.
Old 16-02-2020, 11:11 AM
  #1574  
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Originally Posted by Glenn_
Yeh it's not bad. Miles better than it was. It's never gonna be concours but I just want it to look right and be right.
Good work Glenn, I bet you were suprised at the rusty spots you found. Back in the day Ford made no attemp to rust proof the cars and with the salty shit we get on our roads they will rust. I am glad mine is in good condition despite it having done 110k miles which is down to it being waxoyled from new. I am doing some work on mine soon but it is only for cosmetic reasons not rust issues.There are 2 tiny spots where the underseal has come off and exposed the metal so I am going to clean it up and spray new waxoyle underseal plus gloss black some other parts.There are some bad stone chips on the bonnet so I am having it repainted to smarten it up again.Most people think mine is in good condition but as you say if there are parts which you are not happy with get them fixed.This year I have had mine for 25 years and I still love it!!!
Old 16-02-2020, 12:13 PM
  #1575  
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Did you get your clutch/gearbox issue sorted in the end Glenn ?
Old 16-02-2020, 08:26 PM
  #1576  
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Good to see the old girl having a bit of TLC mate . I'm pulling the motor out of my 3dr very soon so it might be like the good old days getting the post,s up and running again
Old 17-02-2020, 04:39 AM
  #1577  
Glenn_
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Originally Posted by cossynut2
Good work Glenn, I bet you were suprised at the rusty spots you found. Back in the day Ford made no attemp to rust proof the cars and with the salty shit we get on our roads they will rust. I am glad mine is in good condition despite it having done 110k miles which is down to it being waxoyled from new. I am doing some work on mine soon but it is only for cosmetic reasons not rust issues.There are 2 tiny spots where the underseal has come off and exposed the metal so I am going to clean it up and spray new waxoyle underseal plus gloss black some other parts.There are some bad stone chips on the bonnet so I am having it repainted to smarten it up again.Most people think mine is in good condition but as you say if there are parts which you are not happy with get them fixed.This year I have had mine for 25 years and I still love it!!!
yeh I was a bit suprised. I knew the jacking points were fooked cause the way they looked. I took the rear axle out then got the hammer out and only found this bit on the rear chassis leg. I had the passenger side rear chassis leg where the beam bolts to weled years ago
Old 17-02-2020, 04:42 AM
  #1578  
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Originally Posted by scoooby slayer
Did you get your clutch/gearbox issue sorted in the end Glenn ?
Yeh I was lucky that a member on here put a post up saying he had a few bits he was clearing out of his garage and if they were gone by the end of the week he was putting it all in the skip.

I got a gearbox and 8 alloys off him lol The gearbox cured the noise and the clutch bedded itself in too cause the new clutch was slipping at first.
Old 17-02-2020, 04:43 AM
  #1579  
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Originally Posted by COLEYST200
Good to see the old girl having a bit of TLC mate . I'm pulling the motor out of my 3dr very soon so it might be like the good old days getting the post,s up and running again

Thanks yeh I'm just trying to keep her looking the best I can. It's never gonna win any competitions,I just like the cossie to be right.

How come your pulling the engine out??
Old 08-03-2020, 10:31 PM
  #1580  
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Very nice work on the car Glenn. Very lucky finding those jacking point floor panels
Your the same as me. Won't be using them to lift the front end up any more
Old 08-03-2020, 11:38 PM
  #1581  
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pretty good job there Glenn, I did the same on my race car build I bought a full sierra for panel cuts and fitted both jacking points I did however add extra (much thicker) metal to the insides and welded them in before I fitted them, it means I can jack up under them without them crushing like they did originally

Steve
Old 09-03-2020, 07:06 PM
  #1582  
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Originally Posted by Glenn_
My car is in the bodyshop again due to the rear arches been rusty again and the front lips on the wings been rusty too.The lad who owns the bodyshop said to help and to keep the labour costs down that I could strip the car down so all he had to do was the body work.

Attachment 93521

I bit of rust on the osf lip on the wing.
Attachment 93522

Nsr wheel arch.
Attachment 93523

Osr rear arch.
Attachment 93524

Attachment 93525

I found a bit of rust starting on both sills which felt a bit soft to the touch lol.

Attachment 93526

Attachment 93527

Attachment 93528
I got a call off the lad at the bs and said I would have to pop down cause the inner sill was a bit rusty.


Attachment 93529



Attachment 93530

Also in the nsr foot well/floor is also corroded so this will need welding too.

Attachment 93531

So yeh the car needs a bit of tlc.Im popping down this week to so how the progress is coming on.Im dreading getting the other side stripped down cause ive got a funny feeling the other side will be the same.

It just gor me thinking about how many other cosies are like this behind the sills.At the end of the day I love the car and its my hobby so I wanna keep the old girl on the road.

Thanks for looking.
Glen go steady when you strip her down it might be rot holding her together at the min. I’d seriously consider getting the car
to a garage with 2 jacks and carry out the following work:

-jack front number plate up

-jack rear number plate up

-finally drop a new car in, bish bash bosh jobs a gooden fella 👍

no point messing about she’s had more hits than Rihanna
Old 10-03-2020, 07:12 PM
  #1583  
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Originally Posted by kosienutter
Very nice work on the car Glenn. Very lucky finding those jacking point floor panels
Your the same as me. Won't be using them to lift the front end up any more
Very nice job Glenn
i'm joining the club "won't be using them to lift the front end up any more" had them re done to.
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Old 11-03-2020, 08:01 AM
  #1584  
gcfcos
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Cracking job mate. On mine they are slightly crushed and won't be using them anymore to jack the car up!
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Old 01-04-2020, 09:04 PM
  #1585  
Glenn_
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Originally Posted by kosienutter
Very nice work on the car Glenn. Very lucky finding those jacking point floor panels
Your the same as me. Won't be using them to lift the front end up any more

Defo wont be using them..there just for show now lol. How is your saph coming on.
Old 01-04-2020, 09:05 PM
  #1586  
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Originally Posted by The Youth.
pretty good job there Glenn, I did the same on my race car build I bought a full sierra for panel cuts and fitted both jacking points I did however add extra (much thicker) metal to the insides and welded them in before I fitted them, it means I can jack up under them without them crushing like they did originally

Steve
Good idea that Steve.
Old 08-04-2020, 05:55 PM
  #1587  
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Good to see you still got the old girl Glenn 😊 Since selling my Saff I’ve had 2 focus rs mk1’s, s1 rst, escos and now a mk2 frs. I still miss my mercury grey saff 😢 never been taxed or even entered for an mot since I sold it 7yr ago yesterday. Tried contacting the lad I sold it to after I sold the escos and said I’d buy it back at any cost but never even got a reply. Can’t remember what his user name was on here either. My old white shell still sits in a barn up my mates yard but it’s near enough bare. I said to the mrs I should build it back up but it’ll require a fair bit of welding as it wanted innner outter sills 9yr ago. In fact that was the last time I actually looked at it 😂
Old 25-04-2020, 06:51 PM
  #1588  
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I would love an escos. The old Fords are going up in price and so are the parts.
Old 25-04-2020, 06:54 PM
  #1589  
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got the rear end all repainted and built back up. I replaced all 4 cv boots and 2 roll bar links.
Old 25-04-2020, 07:05 PM
  #1590  
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stonechipped the rear of the floor and painted the fuel/brake pipes. Replaced all the fuel pipe clips on the floor and chassis leg.

I started on the fuel pump cradle.

One of the brackets were rotton so I made a new one.

cradle finished,treated with Kurust then painted.
Old 25-04-2020, 07:07 PM
  #1591  
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the piece I'm pointing at was the piece/bracket I made.
Old 25-04-2020, 07:16 PM
  #1592  
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while the exhaust was off I thought I would sort out the fitment of it. It never sat right at the back so I cut about an inch off and adjust the exhaust pipe. The back box fits miles better now.

Then it was time to make a start on the front suspension.

all removed.

both driveshafts stripped regreased and new cv boots fitted.
Old 25-04-2020, 07:25 PM
  #1593  
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Repainting the suspension parts.

freshly painted shock vs old grotty looking shock.


the front subframe/engine bed has always had this damage on the drivers front. I think before my ownership the driveshaft had shut itself and damaged the frame.

old vs new suffrage.
Old 25-04-2020, 07:36 PM
  #1594  
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the new suffragsubframe refitted anti roll bar cleaned and repainted.

all rebuilt. Had a chew on to get the bottom arms back into the hubs.

I removed the front splitter and repainted it using flex paint then refitted it.

Then time to give her a run round the block and give her a wash down.

I refitted the cold air feed pipe to the air filter

Old 25-04-2020, 07:41 PM
  #1595  
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Just some pics after I finished the underside clean up.

A pic of the back box fitting better than it was.

Old 26-04-2020, 12:06 PM
  #1596  
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Looking good. Plenty of room to get around it in your garage.
Old 26-04-2020, 12:09 PM
  #1597  
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Great work all clean and tidy but not overdone that you would be worried about using it, exactly like mine.
Old 27-04-2020, 07:01 AM
  #1598  
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Originally Posted by studabear
Looking good. Plenty of room to get around it in your garage.

Yes I wanted a house with a big garage to keep the cossie in and all my other shit.
Old 27-04-2020, 07:02 AM
  #1599  
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Originally Posted by boost monster
Great work all clean and tidy but not overdone that you would be worried about using it, exactly like mine.

I love the underside of cads painted the same colour as the car but to me that would need more cleaning.
Old 27-04-2020, 09:18 AM
  #1600  
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Great work you have done Glenn, looks very smart now. Looking at the underside of yours compared to mine I have nothing like the problems you have had thankfully.The waxoyle treatment is what I reckon has stopped mine rusting. What I am doing is all cosmetic but I have never really done much to it on the underside in the 25 years I have owned it so with this lockdown it is the ideal time to tidy it up.I have fitted black powdercoated rear brake splash guards and also a black powdercoated fuel pump cradle .Mine will never be concourse but for it's age and mileage it is in pretty good shape and always get's a lot of attention.


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