My 400+bhp CGI Zetec/ST170 Turbo S2 17/05/08 Game Over.
15-08-2005, 10:00 PM
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My 400+bhp CGI Zetec/ST170 Turbo S2 17/05/08 Game Over.
Hi all,
Having won a 1989 Mercury Grey F reg Series 2 Escort RS Turbo MOT failure on ebay for £1000 i thought i'd keep you all in the picture on how she's coming along. Viewing was in the form of phone calls to hear the car running and dozens of emailed pictures. I took a bit of a gamble in doing it this way, but when the car's in kent and you're in yorkshire - you do these things!
However - on collection last wednesday night i was pleasantly surprised. Exterior rust and rot is present, but minimal compared to others i've viewed. There is some rust that needs addressing - inner wings, sills and the bulkhead, however for a £1000 i wasn't expecting a minter!
The car does have some serious benefits:
Cosworth 2WD Disc (drilled & grooved) & Caliper conversion FRONT AND BACK!
Koni adjustable suspension
Fully rebuilt engine
Oh, and i'm finding more bits and bobs like that the harder i look
Found a few tweaky bits like modifications to the turbo for oil cooling etc.
I reckon the turbo might have been re-conned to a 'Stage' as well - will need to get it on the rollers to find out exactly what...
First of all - a side on shot - shows the nice new 16" 6 spokes that came on the car!!!
Put smoked rear lights in!
Replaced old stuff with brand new Roose Motorsport hose and Forge Motorsport dump valve
'The beast' all tucked up ready for bed - awww
Few technical problems so far:
Noticed a backfire under load in 2nd a couple of times...
The end 'nipple' of the water return to the header tank sheared off as i removed the old hose
Investigating the first problem...
Needed an excuse for a shiny new header tank... oh well
***Update - 13/08/2005***
Right.
The car in itself IS an MOT failure - i knew this when i bought it and its due to 'corrosion to the structure' - so i thought today i'd strip out the interior (entirely) and see exactly what i could see...
This is the devastation i caused in around 1 hour
Passenger seat out (need somewhere to sit while i do all the steering column!)
Nope. All this needs to go too
Gone
Interior coming away nicely now...
Oh god... what have i started...
***Update 14/08/2005***
Very constructive day today - spent about 8 hours on the car
All started with me carrying on the removal of the interior:
So with the seats out - i thought i'd peel back the carpet:
Carpet completely out:
Worryingly - as i removed the top layer of carpet - the sound deadening layer felt VERY wet - I think this was the cause of some of the rust - wet material against metal for a long period of time...
Sure enough - the sound deadening carpet layer was sopping wet!
The lawn was filling up nicely
Then my heart started to sink. The few flakes of rust i'd found and wanted to investigate suddenly seemed the tip of the iceberg :shock:
Time to COMPLETELY empty the car
A lot of the sound deadening sheets had started to split and crack - so i decided to chisel them off... great idea when you start
The whole inside of the car'll be getting a thorough clean up and possibly a respray...
**Update 15/08/2005**
Right - a slightly more eventful day than planned...
Involved a 4 hour trip to casualty
Really big tip guys - when working on cars...
WEAR SAFETY GEAR!
Nearly lost the sight in my left eye today after the back windscreen shattered as i was removing it - had a splinter of glass removed and have a nice week of ointments, drops and god knows what else to look forward to
Eh well, chiseled a load more sound deadening out today.
Also made a start on removing the sunroof and headlining.
Looking more and more ready for the welding and respray!
And then it all went pear shaped
At that point i left for casualty
Having won a 1989 Mercury Grey F reg Series 2 Escort RS Turbo MOT failure on ebay for £1000 i thought i'd keep you all in the picture on how she's coming along. Viewing was in the form of phone calls to hear the car running and dozens of emailed pictures. I took a bit of a gamble in doing it this way, but when the car's in kent and you're in yorkshire - you do these things!
However - on collection last wednesday night i was pleasantly surprised. Exterior rust and rot is present, but minimal compared to others i've viewed. There is some rust that needs addressing - inner wings, sills and the bulkhead, however for a £1000 i wasn't expecting a minter!
The car does have some serious benefits:
Cosworth 2WD Disc (drilled & grooved) & Caliper conversion FRONT AND BACK!
Koni adjustable suspension
Fully rebuilt engine
Oh, and i'm finding more bits and bobs like that the harder i look
Found a few tweaky bits like modifications to the turbo for oil cooling etc.
I reckon the turbo might have been re-conned to a 'Stage' as well - will need to get it on the rollers to find out exactly what...
First of all - a side on shot - shows the nice new 16" 6 spokes that came on the car!!!
Put smoked rear lights in!
Replaced old stuff with brand new Roose Motorsport hose and Forge Motorsport dump valve
'The beast' all tucked up ready for bed - awww
Few technical problems so far:
Noticed a backfire under load in 2nd a couple of times...
The end 'nipple' of the water return to the header tank sheared off as i removed the old hose
Investigating the first problem...
Needed an excuse for a shiny new header tank... oh well
***Update - 13/08/2005***
Right.
The car in itself IS an MOT failure - i knew this when i bought it and its due to 'corrosion to the structure' - so i thought today i'd strip out the interior (entirely) and see exactly what i could see...
This is the devastation i caused in around 1 hour
Passenger seat out (need somewhere to sit while i do all the steering column!)
Nope. All this needs to go too
Gone
Interior coming away nicely now...
Oh god... what have i started...
***Update 14/08/2005***
Very constructive day today - spent about 8 hours on the car
All started with me carrying on the removal of the interior:
So with the seats out - i thought i'd peel back the carpet:
Carpet completely out:
Worryingly - as i removed the top layer of carpet - the sound deadening layer felt VERY wet - I think this was the cause of some of the rust - wet material against metal for a long period of time...
Sure enough - the sound deadening carpet layer was sopping wet!
The lawn was filling up nicely
Then my heart started to sink. The few flakes of rust i'd found and wanted to investigate suddenly seemed the tip of the iceberg :shock:
Time to COMPLETELY empty the car
A lot of the sound deadening sheets had started to split and crack - so i decided to chisel them off... great idea when you start
The whole inside of the car'll be getting a thorough clean up and possibly a respray...
**Update 15/08/2005**
Right - a slightly more eventful day than planned...
Involved a 4 hour trip to casualty
Really big tip guys - when working on cars...
WEAR SAFETY GEAR!
Nearly lost the sight in my left eye today after the back windscreen shattered as i was removing it - had a splinter of glass removed and have a nice week of ointments, drops and god knows what else to look forward to
Eh well, chiseled a load more sound deadening out today.
Also made a start on removing the sunroof and headlining.
Looking more and more ready for the welding and respray!
And then it all went pear shaped
At that point i left for casualty
Last edited by Big Will_; 16-05-2008 at 11:04 PM. Reason: Because VBull won't let me have more than 20 pics in one post!
16-08-2005, 12:47 PM
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bargain of a car mate, got a tip for ya if ya want it, heat up the old soundproofing with a blowtorch and use a wallpaper scraper to ease it off, much easier cus it goes all hard and brittle innit. hope this helps. 
Trending Topics
ive been warned about them!!
16-08-2005, 02:40 PM
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Turbo Touch - you are right to have been warned mate...
The engine's supposedly been rebuilt - but sounds like a diesel transit off boost and has misfired on me a few times...
I've just started stripping the engine bay out and when i took the battery out - thought 'battery tray'll need doing' - i've just nearly cried as i found that there is nothing but a big hole under the battery tray now i've knocked all the rust out
At what point does a shell become irrepairable guys?
I really don't want to have to scrap it and re-shell the good bits or sell for parts...
But i really am wondering:
The engine's supposedly been rebuilt - but sounds like a diesel transit off boost and has misfired on me a few times...
I've just started stripping the engine bay out and when i took the battery out - thought 'battery tray'll need doing' - i've just nearly cried as i found that there is nothing but a big hole under the battery tray now i've knocked all the rust out
At what point does a shell become irrepairable guys?
I really don't want to have to scrap it and re-shell the good bits or sell for parts...
But i really am wondering:
16-08-2005, 03:44 PM
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well if it isnt me old college buddy! 
so u finally found urself an RST then mate. well good luck with it m8 n i'll look forward to see hw its goin in here.
u spanner gettin glass in ur eye! glad to see ur listenin to the college wen they tell u to wear safety gear etc etc
J
(ex resident of flat 29
)
so u finally found urself an RST then mate.
well good luck with it m8 n i'll look forward to see hw its goin in here. u spanner gettin glass in ur eye! glad to see ur listenin to the college wen they tell u to wear safety gear etc etc
J
(ex resident of flat 29
)
16-08-2005, 03:57 PM
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Dont see why not, anything can be done you will just have to find a skilled body shop to do it. If they dont plate it, they will prob get the whole pannel renewed or use a bit of the new pannel.
16-08-2005, 04:48 PM
#15
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buy yourself a battery tray with support panel and a right side front inner arch, and you got everything there you need to repair this bit
cost you about 30 quid for the bits from Hadrian Panels
cost you about 30 quid for the bits from Hadrian Panels
16-08-2005, 10:37 PM
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Looking good mate. Seen a lot worse!!!!! My old S2's soundproofing was like that, all wet an just ripped removing it, and stunk, yuk.
As mentioned anything is repairable! to an extent! lol
Keep up the good work i say
As mentioned anything is repairable! to an extent! lol
Keep up the good work i say
16-08-2005, 11:06 PM
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Cheers for all the replies guys - i'll try the technique on the remaining sound deadening tomorrow - had thought about but then decided against it thinking i'd probably set fire to myself/the car/both of us 
Adam - was a keen follower of your S2 Track car project - so you may well yet get a PM with half a dozen questions in
The car just keeps on showing bits of rust - just working my way round deciding what needs welding and what i can get away with on just filler and love
some photo's to follow
Adam - was a keen follower of your S2 Track car project - so you may well yet get a PM with half a dozen questions in
The car just keeps on showing bits of rust - just working my way round deciding what needs welding and what i can get away with on just filler and love
some photo's to follow
16-08-2005, 11:31 PM
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It all started out quite well today - whipped the heater matrix out, took the ECU out and took the battery out.
Then it started to go a bit worse
I thought - it'll need a new battery tray for sure...
Then i thought 'ah'.
Figured i'd cheer myself up and take the rest of the dash out...
Then i thought i'd take the rest of the soggy sound deadening out...
Was met with a shower of rust
However - there was light at the end of the tunnel. When i say tunnel i mean i could see light through the top of the footwell through the fookin battery tray
Moved on to do a bit more on the body to try and take my mind off... Thought i'd take the bodykit off...
This is how the car looked when i packed up after 10 hours on her:
Then it started to go a bit worse
I thought - it'll need a new battery tray for sure...
Then i thought 'ah'.
Figured i'd cheer myself up and take the rest of the dash out...
Then i thought i'd take the rest of the soggy sound deadening out...
Was met with a shower of rust
However - there was light at the end of the tunnel. When i say tunnel i mean i could see light through the top of the footwell through the fookin battery tray
Moved on to do a bit more on the body to try and take my mind off... Thought i'd take the bodykit off...
This is how the car looked when i packed up after 10 hours on her:
17-08-2005, 06:21 AM
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your doing so well mate, just keep stripping it, the more you strip the more rust you will find but then at least you know what your dealing with. keep up the good work!
17-08-2005, 08:06 AM
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Aye, cheers for the support mate!
The only problem is now i've got to order in these new panels to weld in - and having never really had to get hold of them myself - i'm pretty unsure of exactly what i need...
Like i looked for a new pair of sills and there are "skin sills" "full sills" "inner sills" and i'm just sat there giving it the old face...
Anyone fancy explaining to me what i'll need
The only problem is now i've got to order in these new panels to weld in - and having never really had to get hold of them myself - i'm pretty unsure of exactly what i need...
Like i looked for a new pair of sills and there are "skin sills" "full sills" "inner sills" and i'm just sat there giving it the old
face...Anyone fancy explaining to me what i'll need
17-08-2005, 08:58 AM
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Adam - was a keen follower of your S2 Track car project - so you may well yet get a PM with half a dozen questions in
Although, my thread in the resto section is here: https://passionford.com/forum/viewto...853&highlight= if your interested 
17-08-2005, 12:26 PM
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well u can buy each panel individually , think im right in saying that a "full sill" is exactly what it says the full sill inside and outside , the "inner sill" is the bit your front seats bolt next to and they usually go around there, the "skin sill" is just the ouside of the sill . hope this helps .
cheers mark.
cheers mark.
17-08-2005, 01:33 PM
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I'm getting to the point where i'm looking at reshelling 
I had a chat with my mate this morning and he reckons that it's going to be a mission welding it all...
I've only got a very limited budget - and for what i'm going to pay for:
A tailgate
A 90 spec spoiler
A 90 spec bumper
A drivers side door
2 sills
2 inner wings
A cross member
A battery tray
A battery tray support panel
It'd be cheaper to reshell
I had a chat with my mate this morning and he reckons that it's going to be a mission welding it all...
I've only got a very limited budget - and for what i'm going to pay for:
A tailgate
A 90 spec spoiler
A 90 spec bumper
A drivers side door
2 sills
2 inner wings
A cross member
A battery tray
A battery tray support panel
It'd be cheaper to reshell
17-08-2005, 08:12 PM
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Ok.
The re-shell idea is a go ahead...
I figured i wasn't going to get change from £400 in panels, that's before spraying, fitting etc.
So i had a look on ebay for an RS Shell, found out 40 miles away so rang my mate who does all my bodywork - he came round, we went over and i bought it - £500.
It's in white, not ideal - but mint.
The only thing wrong with it:
Scuttle panel at the bottom of the A pillars is slightly corroded on the surface and there's a little bit of surface corrosion on the passenger side sill:
It came as a rolling shell with virtually everything in/on it - bar an engine and ECU, and the interior.
As the advert said:
ESCORT RS TURBO ROLLING SHELL
WHITE 1990 WITH ALL DOCS
BOOT,DOORS AND SUNROOF COMPLETE WITH GLASS AND ELEC MOTORS
FULL BODY KIT AND BUMPERS
RS ALLOYS
COMPLETE SUSPENSION
ALOT OF PARTS : UNTOUCHED BRAKING SYSTEM GEARBOX, FUEL METER,HOSES
STARTER,ALTERNATOR ETC
DASHBOARD 1OO% INTACT
100% SOLID SHELL, COUPLE OF VERY SMALL RUST (2 PENCE SIZE) 80% TRIM INCLUDED
***
Collecting it on saturday hopefully subject to trailer availability...
The re-shell idea is a go ahead...
I figured i wasn't going to get change from £400 in panels, that's before spraying, fitting etc.
So i had a look on ebay for an RS Shell, found out 40 miles away so rang my mate who does all my bodywork - he came round, we went over and i bought it - £500.
It's in white, not ideal - but mint.
The only thing wrong with it:
Scuttle panel at the bottom of the A pillars is slightly corroded on the surface and there's a little bit of surface corrosion on the passenger side sill:
It came as a rolling shell with virtually everything in/on it - bar an engine and ECU, and the interior.
As the advert said:
ESCORT RS TURBO ROLLING SHELL
WHITE 1990 WITH ALL DOCS
BOOT,DOORS AND SUNROOF COMPLETE WITH GLASS AND ELEC MOTORS
FULL BODY KIT AND BUMPERS
RS ALLOYS
COMPLETE SUSPENSION
ALOT OF PARTS : UNTOUCHED BRAKING SYSTEM GEARBOX, FUEL METER,HOSES
STARTER,ALTERNATOR ETC
DASHBOARD 1OO% INTACT
100% SOLID SHELL, COUPLE OF VERY SMALL RUST (2 PENCE SIZE) 80% TRIM INCLUDED
***
Collecting it on saturday hopefully subject to trailer availability...
17-08-2005, 11:23 PM
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Well here's the strange thing - "TurDbo Touch Motorsport" plastered all over it - and there's FOOK ALL been done with the engine
Made around 8psi of boost - and from what pulling apart i've done... The ECU hasn't been opened (still got the warranty sticker WELL AND TRULY non tampered with) - there's a bleed valve that's opened maybe the same amount as if you let an ant run at it...
Unless they were employed to 'do' engine work and did nothing but empty a truckload of cable ties into the engine bay (absolutely every last thing has at least 1 cable tie on)
I won the car on Ebay - what attracted me to it was the recon'd turbo, the konis, the cossie brake conversions, the decent nick interior, the brand new wheels and tyres and the fact it 'supposedly' had a rebuilt engine...
Now the engine has 'supposedly' been rebuilt... but i reckon its got a dry tappet as it sounds like a diesel transit off boost... So i'll strip the block and rebuild it later this week.
Fear not. TurDbo Touch shall not be adourning the new car
Made around 8psi of boost - and from what pulling apart i've done... The ECU hasn't been opened (still got the warranty sticker WELL AND TRULY non tampered with) - there's a bleed valve that's opened maybe the same amount as if you let an ant run at it...
Unless they were employed to 'do' engine work and did nothing but empty a truckload of cable ties into the engine bay (absolutely every last thing has at least 1 cable tie on)
I won the car on Ebay - what attracted me to it was the recon'd turbo, the konis, the cossie brake conversions, the decent nick interior, the brand new wheels and tyres and the fact it 'supposedly' had a rebuilt engine...
Now the engine has 'supposedly' been rebuilt... but i reckon its got a dry tappet as it sounds like a diesel transit off boost... So i'll strip the block and rebuild it later this week.
Fear not. TurDbo Touch shall not be adourning the new car
21-08-2005, 07:16 PM
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Hi guys,
There'll be a full update tomorrow - been busy this weekend to say the least, just got home from a cracking day out at RS Owners Club National Day
The white shell was collected yesterday and the next few days will be spent triple checking there's nothing left worth having off the grey one - then it'll be scrapped
Then a 2 week based rebuild of the white one with everything off the grey one
There'll be a full update tomorrow - been busy this weekend to say the least, just got home from a cracking day out at RS Owners Club National Day
The white shell was collected yesterday and the next few days will be spent triple checking there's nothing left worth having off the grey one - then it'll be scrapped
Then a 2 week based rebuild of the white one with everything off the grey one
22-08-2005, 06:53 PM
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I'll keep the new shell white mate - i reckon white can look spot on when its nice and fresh...
I'll cut it back and polish it for now, then look at spraying it in the spring next year
I kinda wanted to do it grey and keep the other reg - but the DVLA got on there high horse and were on about Q plating it
Ah well - fingers crossed it won't rain tomorrow!
I'll cut it back and polish it for now, then look at spraying it in the spring next year
I kinda wanted to do it grey and keep the other reg - but the DVLA got on there high horse and were on about Q plating it
Ah well - fingers crossed it won't rain tomorrow!
24-08-2005, 09:40 PM
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***Update 24/08/2005***
Will's guide to impressing your parents
First of all:
Place entire Mongoose Exhaust system in garden
Then - park a donor shell.... on the front lawn
Strip new shell to add to general RS parts department/garage...
And take up spraying in the first available place
:P
On a serious note though - the last few days have been taken up with the collection of the new shell and the stripping of it.
I had a *slight* accident yesterday that nearly killed me - stupidly i jacked up one side a fraction more to allow me to get right under a very badly corroded bolt - and as i pulled on the breaker bar, the grey shell collapsed off its axle stands - nearly on top of me - fortunately heard it creaking and rolled out only catching the front bumper on the side of my ribcage and shoulder...
Because the grey shell at the time was stripped of all but one wheel - it went down floorpan flat to the drive... (that one wheel probably saved me some serious injuries!)
So we decided that one corner at a time we'd jack it up and put the wheels back on so we could move it onto the lawn... And what happens? We used one of the axle stands that had earlier been crushed under the shell by mistake - and as i go to put the wheel on and give it a shove to ensure its sat against the hub - the shell goes down again - trapping my hand on top of the wheel with the arch... Now have a nice gash and some serious bruising across the top of my hand to go with my aching ribs and shoulder :P
I reckon this RS knows its going to the scrappers
The white one is stripped and only needs a quick drop of weld before i can start reassembling the interior (found a tiny bit of rust at the back of the floorpan)...
Gave the rocker cover a quick rub down and coat of white paint this evening - will give it a few more rubdowns and coats tomorrow... Brighten the engine bay up a little...
Sadly a family crisis has prevented me doing more work - but hopefully the next few days will show further progress
Will's guide to impressing your parents
First of all:
Place entire Mongoose Exhaust system in garden
Then - park a donor shell.... on the front lawn
Strip new shell to add to general RS parts department/garage...
And take up spraying in the first available place
:P
On a serious note though - the last few days have been taken up with the collection of the new shell and the stripping of it.
I had a *slight* accident yesterday that nearly killed me - stupidly i jacked up one side a fraction more to allow me to get right under a very badly corroded bolt - and as i pulled on the breaker bar, the grey shell collapsed off its axle stands - nearly on top of me - fortunately heard it creaking and rolled out only catching the front bumper on the side of my ribcage and shoulder...
Because the grey shell at the time was stripped of all but one wheel - it went down floorpan flat to the drive... (that one wheel probably saved me some serious injuries!)
So we decided that one corner at a time we'd jack it up and put the wheels back on so we could move it onto the lawn... And what happens? We used one of the axle stands that had earlier been crushed under the shell by mistake - and as i go to put the wheel on and give it a shove to ensure its sat against the hub - the shell goes down again - trapping my hand on top of the wheel with the arch... Now have a nice gash and some serious bruising across the top of my hand to go with my aching ribs and shoulder :P
I reckon this RS knows its going to the scrappers
The white one is stripped and only needs a quick drop of weld before i can start reassembling the interior (found a tiny bit of rust at the back of the floorpan)...
Gave the rocker cover a quick rub down and coat of white paint this evening - will give it a few more rubdowns and coats tomorrow... Brighten the engine bay up a little...
Sadly a family crisis has prevented me doing more work - but hopefully the next few days will show further progress