[phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 483: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/bbcode.php on line 112: preg_replace(): The /e modifier is no longer supported, use preg_replace_callback instead [phpBB Debug] PHP Warning: in file [ROOT]/includes/functions.php on line 4752: Cannot modify header information - headers already sent by (output started at [ROOT]/includes/functions.php:3887) [phpBB Debug] PHP Warning: in file [ROOT]/includes/functions.php on line 4754: Cannot modify header information - headers already sent by (output started at [ROOT]/includes/functions.php:3887) [phpBB Debug] PHP Warning: in file [ROOT]/includes/functions.php on line 4755: Cannot modify header information - headers already sent by (output started at [ROOT]/includes/functions.php:3887) [phpBB Debug] PHP Warning: in file [ROOT]/includes/functions.php on line 4756: Cannot modify header information - headers already sent by (output started at [ROOT]/includes/functions.php:3887) RS Motorsport :: Classic Speed Restored • View topic - Mk2 Rs2000 Restoration
Hi all, a NEW thread in Projects! well I never....
So, this is a car that i've had in the shop for a bit over a year now, It's not mine but has been entrusted to me to perform a restoration with some minor modifications along the way.
It's been a busy year for me with shed infrastructure being the main focus, installing a 7.5kW compressor and airlines and the biggie, designing/building/installing a spraybooth.
But anywho, this thread is about the RS2000 and i've been trying to keep a video build as well as heaps of pics.
This would have to be about the best condition Escort shell that i've ever seen, apart from the 4 door ghia in my other thread. By the looks of things it was last registered in 1988 and to my reckoning has 39000 or so original k's on it. The major flaw with it is it has rust worms almost everywhere (you'll see in the pics later) which means a bare metal resto is required in most places to grind it out and rust convert it.
I haven't tackled the bonnet yet, but it and the roof have had an additional coat of paint at some stage. the roof looks as though its seen a hailstorm at some point in its life but the top of the front guards are unmarked.
The outlet of the gearbox is exactly where it is with the 4 speed in it. The mount in the 5 speed is 20mm lower and 40mm rearwards of the 4 speed, hence the need to drop the mounts by 20mm and move them back in the tunnel 40mm.
The next video is the beginning of the tunnel mods for fitting the 5 speed. Because the gearlever hole has to be moved rearward by 70mm i also like to move the handbrake back otherwise the gearlever and boot gets very close to it. The practical limit is 50mm and is a pretty easy mod to do. The only other thing needed is a 50mm spacer to go between the cable and the cable/adjuster bracket at the rear of the tunnel.
For the console, i eventually want to make a fibreglass replica that incorporates the 70mm extension. All the consoles that i have are falling apart anyway.
Moving along, the next step was to tackle the engine bay (about early October 2016). The spraybooth was getting towards completion and the compressor was installed with the airlines all plumbed in, so i got back to working on the RS.
I stripped a test area with a 2" roloc abrasive pad which only removes the paint and doesn't attack the steel. Once cleaned of paint, the rust 'worm' was very evident. It was almost like a scab on a wound, in that it sat proud of the metal surface. I then used an 80 grit disc to break into the scab and grind away as much of the rust as i could.
Having decided that to mechanically strip the rust affected areas would take way too long, i took to the engine bay with paint stripper, making sure to keep the stripper away from any crevices that would retain the stripper and lead to more rust. Anywhere the stripper couldn't be used, i used the 2" roloc abrasive disc.
I kept each area to a day's work: strip, clean, rust grind then rust convert.
The rust converter I was using at the time was Austech, and all appeared to be working well. Once the area was stripped and cleaned, i applied the rust converter. It was recommended to leave it 24 hours to dry as it was a water based product. It was meant to work its way into the rust, neutralise it and leave a surface ready to prime over. After 24 hours of drying the remnants were blasted off with an airline, cleaned and prepped for etch.
This all worked well and the engine bay was complete and in etch (epoxy single pack) withtin a few days. As you can see from the end of the video (linked below), there was a reappearance of some of the rust in the engine bay within a couple of months. Unfortunately dad has had a similar experience with the same product on one of his cars. Where mine had not had a topcoat, his did, but the results were the same. I have since switched to a rust converter (Evaporust) which only converts the rust, it doesn't leave a residue like the Austech stuff did. Only time will tell if it has been successful.
The only 'extra' in the engine bay was to remove the battery tray and make it so that it could be bolted back on. This enabled me to get right behind it to clean it up and rust convert/etch it properly. Also, this car might get a sidedraft carby upgrade in the future and it will be handy to just unbolt the battery tray and get it out of the way. Not a concourse mod, but a practical one.
The whole car's in etch now. Paint stripper was easy to use as the majority of the car was still in its original coat of paint apart from the bonnet, bootlid and roof where it had (what looks like) hail damage repaired. The rust was mainly in the top half of the car (you'll see in later pics).
It would be interesting to see what kind of blasting it would have needed to get rid of the rust as the surface was pretty tough. I've got other escort bits here with rust like that so when i've got the blast shed up and running i'll tackle them.
I just had a bonnet done with some in it and it's all gone but you have be careful not to put too much heat in so I pay a guy at Yamanto who does it with glass
The next installment is the panelwork for the front left guard. It was by far the most messed up panel on the car and needed a bit of panel beating and filler work.
The front left guard had some prior repair work done to it, but it was pretty rough and not the right shape around the rear of the eyebrow.
Once stripped back, the surface rust really stands out. I removed all the old filler before starting on the panelwork.
This was one of the worst surface rust spots.
Filler work almost complete, just a few touch-up bits to go.
Next up was the driver's side guard strip and the door removal. There was literally nothing to do to the front right guard after stripping, rust converting and etching
The doors were in such good alignment I ended up drilling and pinning the hinges before i took them off to make reassembly easier.
The next bit I tackled was around the door openings and the roof. I didn't get much video of this area, and not many pics either. The roof had a single overspray at some point in its life, it looks to me as though the car has seen a hailstorm as the roof, bonnet and bootlid have dents of various sizes in them.
The door surrounds only needed a cleanup and a touch of rust converting. for these areas I used gunwash on a rag to clean off any oily/greasy deposits then some foam backed sanding paper (240 grit) to rough up the paint. I don't know if it was factory, but the door seals were installed on a chewing gum-like sealant which was a complete pain to remove
Moving on, with the right rear finished I worked on the bootlid and the boot surround, including the rear panel which looked a bit out of whack to begin with.