PassionFord - Ford Focus, Escort & RS Forum Discussion
Ghetto jig. The masking tape is used to mark the precise position of where the comp strut mount goes. I have wound the comp strut all the way home and the track control arm is hard against the stop on the cross member so this is the furthest back it can ever be. I have locked off the comp strut so it is fixed length that I can match on the other side.
Ghetto jig. The masking tape is used to mark the precise position of where the comp strut mount goes. I have wound the comp strut all the way home and the track control arm is hard against the stop on the cross member so this is the furthest back it can ever be. I have locked off the comp strut so it is fixed length that I can match on the other side.
0 2022/06/19 09:25:36
Spirit level clamped to the cross member.
Spirit level clamped to the cross member.
0 2022/06/19 09:25:29
Passenger side is 17 mm from the spirit level clamped to the cross member.
Passenger side is 17 mm from the spirit level clamped to the cross member.
0 2022/06/19 09:21:05
Drivers side compression mount about 5mm from the spirit level that I clamped square on the cross member.
Drivers side compression mount about 5mm from the spirit level that I clamped square on the cross member.
0 2022/06/19 09:20:58
Front crossmember on their jig.
Front crossmember on their jig.
0 2022/06/19 09:20:11
0 2022/06/19 09:20:09
Had to add a small extension to the transfer tunnel but not a huge amount. The other side needed more mods.
Had to add a small extension to the transfer tunnel but not a huge amount. The other side needed more mods.
0 2022/06/17 05:33:56
Stitch welded the tunnel so now I can add a thin bead of seam sealer
Stitch welded the tunnel so now I can add a thin bead of seam sealer
0 2022/06/17 05:33:50
There are 4 of these highlighted plates, the front one on the passenger side is 4mm shorter than the one on the drivers side, it seems they may have measured from the back of the shorter one as the measurement is exactly the same as the error.
There are 4 of these highlighted plates, the front one on the passenger side is 4mm shorter than the one on the drivers side, it seems they may have measured from the back of the shorter one as the measurement is exactly the same as the error.
0 2022/06/05 08:03:11
I have cut off the rear section and welded a captive nut on to the plate I have cut out, now I can bolt through and work back to the true centre 4mm forward. Then I will tack that in place and cut off the front which needs to be 62mm in front of the rear plate. This then makes it bang on opposite the other side. I was looking down at the gearbox tunnel wondering why the gear selector was so far off to the passenger side…4mm at the front equates to a massive deviation that far back.
I have cut off the rear section and welded a captive nut on to the plate I have cut out, now I can bolt through and work back to the true centre 4mm forward. Then I will tack that in place and cut off the front which needs to be 62mm in front of the rear plate. This then makes it bang on opposite the other side. I was looking down at the gearbox tunnel wondering why the gear selector was so far off to the passenger side…4mm at the front equates to a massive deviation that far back.
0 2022/06/05 07:46:38
Passenger side
Passenger side
0 2022/06/05 03:14:42
Drivers side
Drivers side
0 2022/06/05 03:14:34
I also used metal squares to check.
I also used metal squares to check.
0 2022/06/05 02:50:50
0 2022/06/05 02:50:42
Spacer hard against the tunnel.
Spacer hard against the tunnel.
0 2022/06/04 08:20:41
0 2022/06/04 08:20:35
0 2022/06/04 08:20:30
You can see the selector cradle hard against the tunnel. I will shave off lots of the cradle to allow more room….obviously there will be some engine and box movement.
You can see the selector cradle hard against the tunnel. I will shave off lots of the cradle to allow more room….obviously there will be some engine and box movement.
0 2022/06/04 08:20:25
I roughly cut the tunnel to allow the selector to come up through the tunnel.
I roughly cut the tunnel to allow the selector to come up through the tunnel.
0 2022/06/04 08:20:20
0 2022/06/04 08:20:14
Bolts on the transfer case hit the tunnel, still 25mm to go up yet on the mount.
Bolts on the transfer case hit the tunnel, still 25mm to go up yet on the mount.
0 2022/06/04 08:20:07
The gear selector cradle hits the tunnel before the gearbox goes all the way up on the mount.
The gear selector cradle hits the tunnel before the gearbox goes all the way up on the mount.
0 2022/06/04 08:20:02
Transfer box also hit the back of that tunnel piece….Mr plasma was out again.
Transfer box also hit the back of that tunnel piece….Mr plasma was out again.
0 2022/06/04 08:19:57
The spacer hits the tunnel even with 25mm to go up on the gearbox mount.i had to cut the tunnel out. I will be able to shave a few mm off the spacer and then make a very low profile box to seal up the tunnel. I need to buy a new slave cylinder as my one with dry break hydraulics went walkies.
The spacer hits the tunnel even with 25mm to go up on the gearbox mount.i had to cut the tunnel out. I will be able to shave a few mm off the spacer and then make a very low profile box to seal up the tunnel. I need to buy a new slave cylinder as my one with dry break hydraulics went walkies.
0 2022/06/04 08:19:51
This is the 1 inch oppliger spacer. It occurs to me that I can lop this corner off…may as well save the weight.
This is the 1 inch oppliger spacer. It occurs to me that I can lop this corner off…may as well save the weight.
0 2022/06/04 08:19:43
Trolley on wheels.
Trolley on wheels.
0 2022/06/04 08:13:38
These 2 show the hotter welds.
These 2 show the hotter welds.
0 2022/06/04 08:13:32
Paul V and a few others have offered tips on welding, generally this was "add more heat"
Paul V and a few others have offered tips on welding, generally this was "add more heat"
0 2022/06/04 08:13:25
0 2022/06/03 09:10:54
I have put a spirit level on the shell and the engine and it does sit dead flat….or atleast will with the gearbox weight on the back as it wants to tilt forward a little now. In this pic you can see the cuts I previously made to the scuttle panel to stop the cam trigger and breather hitting…you can now see how much lower the engine sits. I will fold up some boxes to finish the scuttle, just in case the engine needs to come up a bit.
I have put a spirit level on the shell and the engine and it does sit dead flat….or atleast will with the gearbox weight on the back as it wants to tilt forward a little now. In this pic you can see the cuts I previously made to the scuttle panel to stop the cam trigger and breather hitting…you can now see how much lower the engine sits. I will fold up some boxes to finish the scuttle, just in case the engine needs to come up a bit.
0 2022/06/03 09:10:47
Once I am happy with the exact engine position I will put a plate over the bolt hole on the mount as I had to slot it to get the Dewitts mounts in.
Once I am happy with the exact engine position I will put a plate over the bolt hole on the mount as I had to slot it to get the Dewitts mounts in.
0 2022/06/03 09:10:38
Ready for a test fit of the engine and gearbox. I am going to have a few days off it now and then push on with the engine mock up.
Ready for a test fit of the engine and gearbox. I am going to have a few days off it now and then push on with the engine mock up.
0 2022/05/27 08:24:49
The black bar across the front was an old mount for the rad, I will cut this out now and re do.
The black bar across the front was an old mount for the rad, I will cut this out now and re do.
0 2022/05/27 08:24:40
Quick release spit…..quick released
Quick release spit…..quick released
0 2022/05/27 08:24:30
There wasn’t a weld along this box so that has been done now
There wasn’t a weld along this box so that has been done now
0 2022/05/27 08:24:21
I left 3mm of the old platform poking up from the floor and welded the base to that, then put a thick weld from the old base to the floor as it had only been tacked on this side,
I left 3mm of the old platform poking up from the floor and welded the base to that, then put a thick weld from the old base to the floor as it had only been tacked on this side,
0 2022/05/27 05:30:42
I have put in the L shape on the front cage leg, drivers side. Angled it back towards the cage to keep it as far away from my ankle as poss.
I have put in the L shape on the front cage leg, drivers side. Angled it back towards the cage to keep it as far away from my ankle as poss.
0 2022/05/27 05:30:34
Upper door bar.
Upper door bar.
0 2022/05/27 05:29:08
More sanding and filling today, this was the largest area of damage on the wing. I cannot feel any deviations to the touch now so probably one more coat of high build and block it back and that area should be done. There are about 7 repair areas on this wing as it popped 4 of the filled rivets where it joins the car, another crack like the one in the pic and then a crack up the door pillar and along the window ledge. Nearly all sorted now….I hate body work.
More sanding and filling today, this was the largest area of damage on the wing. I cannot feel any deviations to the touch now so probably one more coat of high build and block it back and that area should be done. There are about 7 repair areas on this wing as it popped 4 of the filled rivets where it joins the car, another crack like the one in the pic and then a crack up the door pillar and along the window ledge. Nearly all sorted now….I hate body work.
0 2022/05/26 10:55:02
0 2022/05/24 10:06:24