rocky_robin

I thought that I'd share this project with you after some 5 on/off years of tackling the neverending rust.

This is my very first car, which I've never sold, due to loving her too much for the fun factor. I tackled this when I was 17 putting on new panels, etc but since nobody was there to tell me what rust was, underseal was just applied over the surface rust.
This then took it's toll over the 2 years and being a student, couldn't afford to fix her again, as well as paying for a rented flat.

I took some pics of what I've being doing, but really it's been cutting ALL rust out and putting in new metal. Every panel has had some work.

You will see from the chassis leg, it was THAT bad. Rumaging about the garage, I came across a Nova front bumper, which was perfect for re-shaping into a new one, as they are no longer available from Ford (surprise, surprise!!)
Door pillars, boot floor (made from a 16i door), arches, floor pan, etc, etc!!!! I've done it all on the cheap, so what ever I could make, I did. Only the door pillers and entire front end was purchased panels.
Entire shell has been seam welded and strengthened at parts (bulkhead), with a few secret mods done too.

Everyone thinks I'm made undertaking such a major job, for just an XR2, but hae it is valuable to me alone. Many things were undertakin in that machine..........!
Best thing is that at least I can say that I've done EVERYTHING myself. Once the rest of the cage is bought and fitted, I'll be building a booth in the garage (totally sealed, with air vents already installed!) and giving painting a shot.

The XR2 engine is now ditched and a RST engine going in. I've a 2.0L Zetec (20K miles) bottom end sitting around so could use that in time.

All of my rebuild has been using my 35mm camera, but only used my rubbish digi cam to show you these. Once IT here at work sort out the scanner, I'll get the other pics to you.


Here she is in her former glory!











(It took over 100 digi photos to capture the last one!)



Dreaded rust............!!! Yes that IS the chassis leg!!

rocky_robin

Full FIA approved cage!

I compared the OMP cage to the Safety Devices cage that I had previously and it's SSSSSOOOOOOOOO much better. Better quality steel as well as larger sections. Best bit is that it's much cheaper than Safety Devices as well as including the FIA approval and door bars. :thumbsup:

rocky_robin

Took a few days off work last week to get her painted and this is her.

Here's the pics of the makeshift booth in my garage.




An old car cover came in handy for covering the dust layer'd rafters above the garage




The garage door was sealed using pipe insulators.

My wee mixing table, outside the booth



On Thursday afternoon, my new HVLP gun arrived, so on goes the primer (2 coats) applied above the paint sealer (3 coats)









On Friday morning, after getting the heaters back on to get it nice and toasty, I proceeded with 3 coats of Moonstone Blue.


After leaving that to heat over night (scared of the heating bill now.....!!), I wipped on the laquer on Saturday morning and got only 2 RUNS! They could have so easily have been N/A, but I moved my legs in the wrong position as I crowched down and put the gun far too close to the metal. Not a good photo of one of the runs, but you get the idea.










Here's the run:


The car is now ready to start bolting everything back together again, then it will be given a good buff to make her all shiny, as you notice the roof is a bit orange peely. the polish will hopefully remove the runs too.

There is a few bits of dust landed on the roof, but what do you expect from a makeshift booth in the garage.

Still VERY chuffed as it was my first attempt of spraying and learned as I went. I bought a book from Amazon, called 'How to paint your car'. Its an American book, but very detailed and got loads of tips on what to purchase.

Shorty

iTrader: (1)

Well done m8 for attempting it all urself...looks like ur doing a good job aswell

Keep up the good work and keep the updates coming

smithy_1980

looking really good mate keep the updates coming

lmans123

top job m8.keep it up

M Brian

impressive!!!

whitecossie

well done mate

Scottish Greg

Robin...

Nice one mate and well done for tackling it yourself

Im not sure the local council would have liked me using my lock-up for re-spraying my FRST
Will be good to see your Fiesta back on the road ......

harvcore

iTrader: (8)

looks good lad ,give me a shout if you need a hand or need spares as im in the aberdeen area and have a xr2 for spares for my one

rocky_robin

Thanks all!

Greg, it feels weird not having to weld or grind, let alone drive the car!!!
Every morning when I go in to get by bike in the garage, I still can't believe that I can start to put things back in again.

I just hope that I can find everything, as it's been in pieces for 5 years and also moved house in 2004.

harvcore, thanks for the help there. I'm sure I have everything, but will never know until I start putting everything back in.
I just need to get some adjustables (looking at Avo's at the mo, but at Ł530 for the set, I'm still scratching my head). Also going to be getting some Wilwood brakes.

THEN, it's on with the rebuild of the engine. I have most parts for it, but will not find out until I've stripped it and fully inspected the whole lot.

I'm hoping for 200bhp from her, but time will be against me to get her going for the summer, so may have to do with standard for now.
The 2l Zetec I have in the garage is also being looked at as an option as it's only got 20K miles on it.

Brookesy

Love the colour and fair play to you for spraying it yourself. Have you tried this website mate it could be of interest to you www.xrtwo.com

rocky_robin

Just logged on. Haven't been on there for a while, but now added a post.

Cheers,
Rob.

M Brian

ah you used to be a member - I can remember yoru flaming exhaust! lol

your car has been off road about as long as mine!! im not even at the starting stage lol

COSSIE CAL

[color=violet]rusty h?nice flamage though! [/color]

Twins

iTrader: (18)

Great project there,well done for having a go at the painting yourself

N1C4T3N

love it m8t the new colour is going to suit it so well keepin the kit black?

rocky_robin

Thanks!

No XR2 should have it's bodykit painted, IMO. Thats what makes the XR2 and XR2. That includes the black window surrounds, which I've still to do.

I'll try and get some of the original stripping and rebuilding photos from the loft and see if I can find a scanner here to post them up.

Cheers,
Robin.

rocky_robin

Since a few have been asking about the cage, here's my reasons.

As I said in the post, the Safety Devices one is so much smaller tubular sized. The OMP is FIA approved (safer), where are the SD one, you have to spend more money for doorbars, which makes it approved. The OMP one comes with the door bars and is far cheaper compared to the SD one.

Here's the breakdown in price:

Safety Devices
Bolt in Front cage = Ł141.57
Rear with removable diaganal (so back seats can be fitted) = Ł191.54.
Doorbars (each) = Ł38.40

Total (exc VAT) = Ł409.91.
Total (inc VAT) = Ł481.64!

I got quoted Ł80 for shipping from their Belgium plant!! That = Ł561.64!!


OMP
Bolt in cage Front, Rear (w/removable dia) & Doorbars Ł374.72 (inc VAT & shipping!!)

No questions really which one to get.

I got the cage from Roelands Race and Rally, who are OMP specialists.
Demon Tweeks quoted me some Ł380 exc VAT!! Just had to call them for a laugh really!

xr3-keith

Nice project m8 keep up the good work and updates coming

rocky_robin

Update!

Well, never got THAT much done over the weekend due to I did however install a CVH into a m8's Mk2 Fiesta.....! It seems to be others than mine.

Anyway, Friday night spent bolting the cage in with all of the new nuts and bolts.
Then up to take off the car cover from the roof rafters so I can get access to the loom, etc hiding up above.

On Sat morning, I got a few hours in, getting the loom sorted as well as washing the bodykit (5 years of garage dust on top!).

I intend getting the dash in tonight, so enable me to move the ECU's to the relevant places, as there's just a mash of wires are the mo.
Also bolt up the fuel tank as well as the fuel lines.

I'll see about getting the rear axle shot blasted and get that painted and bolted back on again. Same goes with the front hubs/tie rods. That will keep me busy up till the weekend.

I'm on the hunt for coilovers (front only - rears will have to be adjustables, due to the rear suspension set up on the Mk2's) and Wilwood 4 pots. Give me a PM / email if you know of any.


Kit after washing


First part to be fitted back to the car.......beesting!

N1C4T3N

rocky_robin

Just found 2 old pics on my mums computer that I must have took a few years back.





Yes, that is the boot floor!!

rocky_robin

Todays pics are again only about 2 hours of work worth!

I took the window screen and side windows down from the rafters - check out the dust!!




Boxes of random pieces!



Steering rack and brake bar ready for a clean up (tonights job)



Pedals and steering wheel braces bolted up, as well as the heater matrix

turbo.jon

Looking good mate

Lambchop

iTrader: (1)

thats comin together nicely rob! cant wait to see it in flesh! hopefully see it this weekend or one night next week

rocky_robin

Cheers guys!

Chop, I'll be at hame this weekend (in the garage of course) so jist pop in past, if you've the time.
Next week will prob be in the garage during some nights ony way.

Well, I've dug out some of my photos from when I picked her up when I was 17, then will bring you through the years & stages.
As the work scanner ain't working, I've taken the pics using my digi camera onto the 35mm film, hence the blurryness.

Here' under the bonnet & interior after she was back at my house.





During rework




New front end



After the first rebuild






Start of the 2nd rebuild. That bucket was just by scrapping off the FIRST attempt of rust / old underseal from the floor pan


Front N/S A-pillar








That arch is enough to scare anyone!




Chassis leg





New chassis leg after being fabricated from a Nova front bumper, as Ford stopped making them!


Rear sills (looking up from the bottom of the rear tyre)


Boot floor (picture taken from the garage floor)


Inner arch after a clean up



Spotted the inner arch chassis a bit rusty, so was taken off and a new part fabricated.






Various pics of the floor before and after....











Boot floor cut out






A new floor in place (made from an old rotten RS1600i door!)



Oh, and here's my runabout..........and next project!!

Willem

you have to be crazy to have taken that on

big credit to you m8!!

N1C4T3N

holy shite m8t there some proper fabrication work gone in to that

Stavros

fair play mate

rocky_robin

I thought that I'd bring you all back up to speed on this!

Well, not much as happened, as such, due to work, socially and fixing other folks cars..........cough, cough!

Anyways, no pics here at work, but I've got the fuel pump fitted neatly under the car, beside the tank. I just need to know where to fit the accumulator, that is if it can be removed completely. Anyone know if a one-way valve used within the fuel system will replace it???

My m8 came through 2 weeks ago and showed me how to polish the paint work with 2000 grade, soap and water. Over a few nights, inc last night (with the help of my fiance) the car is now a hell of a lot more better. It could still be done with more flattening on the roof but I can't be assed!!!

It was a nightmare last night trying to watch American Pie at the same time as screwing the side skirts back on after the polishing! lol!
The rest of the kit will be fitted tonight, so I can get the black surround painted, then windows go in!
Got my Wilwoods delivered the other day, so thats the brakes complete, but that is this weekends job, enabling me to get the shell rolling in the garage, so I can get on with the rebuilding of the engine.

markc

blimey i thought my mini was bad
u done well bud

GazzaG

nice one m8

rocky_robin

Well haven't been on here for a while, so here goes!!!!!!

Firstly you will see a few parts been changed out, namely the track rod ends....nice!



Suspension parts painted using some Offshore special paint




Brake bar & servo attached


Windscreen fitted (without any breakages!!!!)


Brake bias valve in a bit of a state...!!! So much for the Rust eater that its coated in!!!









My saviour been outside on the cold nights (10" of snow outside)


Kit now fitted, making it an XR2 finally!!






Dash and clocks in:


At the weekend, I picked up a few goodies - seats, harnesses, engine, etc, so will get onto that very soon!!

The issue I'm fighting with is that I got a late spec servo but forgot to take the bar and driverside bracket, which I'm trying to hunt down..... anyone have one?????
This is the issue I have at the mo:




The bar is from an early spec but as you will see from the last pic, the bar doesn't fit the bracket.

Adam Ash

WOW


now thats dedication, its like Triggers Broom


you have just inspired me more to get mine sorted m8


oh and regards the brake bar bracket, try www.xr2.com and put an ad in the wanted section, or just move it to where it needs to be and drill 2 more holes (cant see it being a problem unless the pedal box mounts to the studs on the back of the bracket which i cant remember!)


keep us updated m8... theres so many xr2's being made good again this year

jake-cos

iTrader: (4)

[quote="rocky_robin"]
Suspension parts painted using some Offshore special paint


[quote]

PMSL..........what you mean is its painted with knicked paint!!!

thats always the best stuff, you canny beat a freebie!!


keep up the good work!

rstoughy

iTrader: (5)

labour of love there M8

Keep that updates coming

Lambchop

iTrader: (1)

lol@special/nicked paint

i'll need to come see it now that the kit is on

and i forgot to ask you last night about the engine etc that you got!

fiestamk1turbo

just looked through your pics mate all the credit in the world to you great work mate i would have given up with all the rot in the shell but most of us have been there have a look at my mk1 its in the same section

rocky_robin

Another update!

Engine cleaned and ready for painting.










New brake bar and brackets installed





New brake lines are run inside the car, leaving the fuel ones outside.