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1978 Escort MkII
March 28, 2014
1:48 pm
James N
Member
Forum Posts: 26
Member Since:
August 15, 2013
Offline

Here are some photos of my MkII Escort.
It started out when my first Escort (1975 MkI in beautiful condition) was written off and I needed another Escort - anything. It cost $500, has always been mechanically reliable but as you can see, the body was POOR!

http://i.imgur.com/TC6gfQd.jpg


http://i.imgur.com/hKE9V1m.jpg

http://i.imgur.com/o1wmMw1.jpg

http://i.imgur.com/vDGkWMt.jpg

http://i.imgur.com/FnN4bwP.jpg

Driving - Escort MkII / Restoring - Escort MkI
March 28, 2014
2:20 pm
James N
Member
Forum Posts: 26
Member Since:
August 15, 2013
Offline

Then came the opportunity for a "quick tidy-up respray".





I actually drove it there almost like this (it obviously had a driver's door, boot-lid and good wheels). It was only about 3 k's from my place but it got some strange looks!
Then it started...

Some cuts & shuts









(I was to find out later that way too much spray putty got used)






The day I picked it up...


...and drove it home.




All finished.


Or is it??
More rust repair photos to come...

Driving - Escort MkII / Restoring - Escort MkI
April 2, 2014
10:37 am
rustyrs
Eden Hills
Member
Forum Posts: 42
Member Since:
November 5, 2013
Offline

Great photo's James...still awaiting the repairs and paint for mine....and waiting more.....and.....

September 10, 2016
6:54 am
James N
Member
Forum Posts: 26
Member Since:
August 15, 2013
Offline

I cant believe it been two years since I posted the pics above!

Here are some pictures of the cut and shut I did with the notorious heater bubble.

First had to find some donor steel...
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0002_zpsk6i4ntox.jpg

Then cut open the bubble to see just how bad it was...
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0005_zpsrecisbfo.jpg


http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0004_zpsolrtcu3t.jpg

...and then remove by drilling out all the spot welds.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0006_zpsos5e1pgv.jpg

Then came the really scary part - cutting a big hole in the fire wall. Things have to look worse before they get better.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0008_zpsoxruykql.jpg


http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0011_zpsrl2fynew.jpg

New steel cut to shape and ready to go in...
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0014_zpsruyf7xgk.jpg

...and then tacked in place...
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0015_zpsxtaqusld.jpg

... and then welded in place with a little help from a mate.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0016_zpsixlukivl.jpg


http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0019_zpslg2zf4uk.jpg

http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0021_zpsh8zhiozz.jpg

A little primer and paint. (And the heater fan shroud sealed in place)
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0023_zpssw1mrzjs.jpg


http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0029_zpsai9uqb59.jpg

Meanwhile, inside under the dash...
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0024_zpsguhrzhbi.jpg


http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0025_zpssnaxxwzh.jpg

http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0026_zpsoflovirn.jpg

Bubble all prepped and ready to fit.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0034_zpse1zflszr.jpg


http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160723_0001_zpsoizxegdp.jpg

http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160722_0032_zpsnq8cgvkc.jpg

http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160723_0002_zpsvgh0slt8.jpg

Sealed in place and ready to be soft soldered.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Heater%20Bubble/IMG_20160723_0004_zpsbouzugl3.jpg

This job took me about a year to complete as I only had Saturdays to work on it.
The car remained on the road (went through a winter with no heater) and I drove her to work every day during the week.

Driving - Escort MkII / Restoring - Escort MkI
September 11, 2016
3:05 pm
James N
Member
Forum Posts: 26
Member Since:
August 15, 2013
Offline

With the heater bubble area done, next was a couple of other rusty areas in the engine bay - around the driver's side strut turret and under the driver's side bonnet hinge bracket.

There was a rust hole just next to the strut turret reinforcement plate. I ended up having to drill out some of the spot welds on the plate and roll it back to reveal the full extent of the rust. Then grinding back to fresh metal actually revealed a small hole in the cup which houses the strut top mount.

http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Strut%20Turret/IMG_20160723_0006_zpsjrrnge2k.jpg


http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Strut%20Turret/IMG_20160723_0008_zpszkq3n5y4.jpg

As always, the time consuming process of cleaning the area back to shiny, bare, rust free metal was next. Lots of phosphoric acid, scratching and scraping to get right into all of the pits in the steel. I got carried away and forgot to take a photo of the bare steel but in this photo of the primed area, you can see the filled hole in the top mount retainer cup.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Strut%20Turret/IMG_20160723_0010_zpsjd6hdr3n.jpg

Then it was time to make a patch to fill the next hole.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Strut%20Turret/IMG_20160723_0011_zpsekvdlmpk.jpg

And here it is after being welded in.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Strut%20Turret/IMG_20160723_0012_zpsvq2ci7es.jpg

After paint it was then time to roll the reinforcement plate back down, seal and plug weld the original spot welds.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Strut%20Turret/IMG_20160723_0014_zpshk90kius.jpg

Then came the repair under and around the bonnet hinge bracket.
As with the strut turret, there are three layers of steel here. I just had to start cutting to figure out how the factory put it together and then come up with a plan. The inner wing is first, followed by the fire wall folded over the top and thirdly the steel that spans the top rear of the engine bay (with the heater bubble). Actually, there is a fourth layer! The bonnet hinge bracket.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Bonnet%20Hinge/IMG_20160723_0005_zpseinhbkhu.jpg

I decided to completely remove the bonnet hinge bracket to gain better access to the area.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Bonnet%20Hinge/IMG_20160723_0015_zpsbcycroyy.jpg

This photo shows the makeshift bracket I bolted on as a temporary mount for the bonnet hinge so I could still drive the car.
It also shows some of the fresh steel already welded in (got carried away again). The dotted red line is just for the purposes of the photo to show where the weld took place.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Bonnet%20Hinge/10380029_zpsmzclk1ri.jpg

Phase 1 of the repair complete
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Bonnet%20Hinge/10380033_zpsoks88kbl.jpg

Next it was time to make a patch to close in the rest. The holes are to be plug welded to mimic factory spot welds.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Bonnet%20Hinge/34290003_zpsr8ga7fkb.jpg

Patch now welded in and the whole area back to bare metal. Ready to have the bonnet hinge bracket welded back on.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Bonnet%20Hinge/41660009_zpsir7ptdl2.jpg

For some reason I forgot to take a photo of the bracket back in place and the area finished. But you know how it should look :-)

Driving - Escort MkII / Restoring - Escort MkI
September 11, 2016
3:46 pm
James N
Member
Forum Posts: 26
Member Since:
August 15, 2013
Offline

Then came the time to tie it all together and finish off the engine bay (at least around the top)

It was stripped back to bare metal in all remaining areas around the top.
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Finishing%20the%20engine%20bay/35440008_zpstvjuxgzp.jpg


A few patches of thin filler here and there...
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Finishing%20the%20engine%20bay/35440007_zpsbia2d4gt.jpg

Primer (etch first to seal then surfacer)...
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Finishing%20the%20engine%20bay/35440009_zpsvktjv0cy.jpg

...and Satin Brown. Very satisfying :-)
http://i1167.photobucket.com/albums/q622/jamesnewtonp1/Escort%20MkII/Rust%20Repairs/Finishing%20the%20engine%20bay/F44530036_zpspia3sv6u.jpg

So that's my engine bay start to finish. Hope you enjoyed it and perhaps even find it helpful on your resto project.

Driving - Escort MkII / Restoring - Escort MkI
January 14, 2017
4:01 am
rustyrs
Eden Hills
Member
Forum Posts: 42
Member Since:
November 5, 2013
Offline

Wow just looked through the rest a lot of work done mate, well done
Laugh

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