Escort RS2000 4x4 2.0 Turbo Conversion

[blacksofstichill]

Brilliant Love the look of this, mk5 front end that is. Looks mean as fook!

 

That is one mental journey to make! Why not have you build the engine and courier it down here though???

 

Thanks, yeah, I love how it looks from the front end too, very mean! You're right, it was certainly a long journey to make for the car to get up here! The original plan was for me to build the engine and then send it down but the car itself was due an MOT, needing some welding and also needing the engine fitted which is quite involved when you take into account it's going to be converted to Turbo. So he decided to bring it up to me so he could basically get the whole job done at the one place rather than get the welding done one place, engine fitted at another, etc. It turned out to be a much larger job than either of us anticipated (for welding work) but we've stuck with it and it's getting there.

 

 

Another update on this, I fully welded up my crossmember mounting repair section on the inside of the car, I built up heavy fillet welds in all of the corners and ground them back so there is plenty of strength in it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0722.jpg

 

Looking at it from the outside you can see I still need to make a plate to fill in the hole at the front and a small infill piece to the inner sill -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0723.jpg

 

Plate made for the front -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0724.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0725.jpg

 

Small infill plate made for the inner sile side -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0726.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0727.jpg

 

Viewed from underneath you can see that all 3 plates I made for this repair are fully welded to each other and they are all welded back to good solid original metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0728.jpg

 

Looking from the inside of the car now you can see where my last couple of plates have filled in the gaps nearest to the inner sill -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0729.jpg

 

Now I need to weld a plate in to the inner arch of the car to cover the area I had cut out, it's an awkward shape but this plate can be formed in place to cover most of it in one go -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0730.jpg

 

With it all welded into place I'm only left with a small gap in the middle of the left hand side which goes around the corner towards the front of the car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0731.jpg

 

Plate cut to suit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0732.jpg

 

Welded into place and all of the welds ground back, this didn't photograph very well with the reflection off the shiny plate -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0733.jpg

 

Looking back underneath again, the chassis rail had a small hole in it which I ground back until I had good clean metal to weld to -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0734.jpg

 

Plate cut to shape -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0735.jpg

 

and welded into place, you can see here that this repair is also tied into my crossmember repair section -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0736.jpg

 

A small hole on the bottom of the chassis rail was also ground back to clean metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0737.jpg

 

Plate made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0738.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0739.jpg

 

When I'd been working inside the car I'd noticed that the floorpan in that corner didn't feel very strong and was ropey at the front edge, holes were very easily poked through it and became clear it wasn't very well welded on the inner sill side either -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0740.jpg

 

This area had been plated before but the plate was very thin indeed and after a few years worth of corrosion it meant the plate was very weak -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0741.jpg

 

Viewed from underneath you can see it isn't very well attached to the inner sill any more -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0742.jpg

 

So, I cut that complete section of floor out between the chassis rails and the inner sills -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0743.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0744.jpg

[lee grout]

Bloody rust!

 

I was also gonna ask, Why turbo a RS2k lump instead of a zetec? I always heard that zetecs are better than the other, just curious?

[sidrick]

Off topic, but do you use/recommend anyone for gearbox or differential rebuilds, or do you do it all yourself?

[blacksofstichill]

Bloody rust!

 

I was also gonna ask, Why turbo a RS2k lump instead of a zetec? I always heard that zetecs are better than the other, just curious?

 

Got to love the rust to keep you busy eh! The reason it was an RS2000 engine being used is mostly down to that being what the original engine was that he bought years ago. Because he already had that engine with Forged Pistons and rods, etc it made more sense to use those parts as a basis for a new build than to start a fresh build altogether.

 

To be honest though, unless he had some trick Zetec Parts lying around already I'd probably still have converted an RS engine rather than a Zetec, mostly just to use the same type of engine that the car was originally fitted with. If it had been a GTI it was going into though, that would have been a different story.

 

 

Off topic, but do you use/recommend anyone for gearbox or differential rebuilds, or do you do it all yourself?

 

Sorry for the delay, I've not updated this for a while! It would depend what it was to be honest, some things I'd tackle myself, others would be a case of sourcing a second hand 'box or diff. I'm not sure but I'd guess that Dingbro will have a company they use for Transmission rebuilds that'll probably be up your way? I can try and find out if that's any help to you?

 

With the section of floorpan cut out at the front I made a repair section to piece into it. I made it so it would fit from above to enable me to weld most of it from inside the car and the lip at the edge is for welding it to the sill from the underside -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0745.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0746.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0747.jpg

 

With the last bit of welding now done on that area of the car I was able to clean back, prime and seam seal that corner of the floor, etc -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0748.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0749.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0750.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0751.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0752.jpg

 

One other area needing attention was the A-Post where the door stay had pulled right out of it-

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0753.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0754.jpg

 

Rather than trying to weld a captive nut back in place which might just pull back out again I decided to cut a slot out of the post, it looks rough here but bare with me -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0755.jpg

 

Cutting that slot out of the post meant I could slot in a heavier gauge plate and weld the post back up in front of it again, so I made a little plate with a captive nut welded to the back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0756.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0757.jpg

 

With the heavy plate slotted in and welded in place I was able to weld up the outer skin of the post again and grind it back, this way the heavy plate with the captive nut is held behind the outer skin of the post as well as being welded to the inner skin of the post so it isn't going to pull out of the post again -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0758.jpg

 

A quick coat of primer and gloss black to protect the bare metal, when it comes to the final clean up of the car I'll most likely paint this again though -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0759.jpg

 

Door Stay bolted back into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0760.jpg

 

Moving on with the rest of the car, I cleaned up the sills along the bottom edge with a wire brush on a drill and the front section of sill is still solid, a bit more time spent cleaning it back and a coat of paint followed by schutz underseal will be all this needs -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0761.jpg

 

Unfortunately the rear end of the sill isn't so good -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0762.jpg

 

wih some more of the loose metal pulled back and looking from underneath you could see the inner sill was also looking like it might be needing some work too -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0763.jpg

 

Outer sill cut back to solid metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0764.jpg

 

 

With the outer sill off in this area you can see that the inner sill also needs to be cut back here too as it's very rusty -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0765.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0766.jpg

 

The inner side of this which is part of the edge of the floor and start of the rear chassis was also crumbling away -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0767.jpg

 

Not to worry though, it can all be cut out and replaced with good metal, so with some angle grinder action I cut out the rusty areas of the inner sill, etc -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0768.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0769.jpg

 

First thing to do now is to cut a flat repair section of sheet to be welded to the remaining flat section of existing inner sill, this also creates a flange I can weld against on the inside and outsde of the sill -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0770.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0771.jpg

 

Now I need to replace the bottom edge of the channel section of inner sill, here is my repair section for it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0772.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0773.jpg

[blacksofstichill]

On the inside of the inner sill, the edge of the floor is quite an awkward shape so I decided to repair it with 3 seperate pieces, starting off at the front and working my way back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0774.jpg

 

First repair section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0775.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0776.jpg

 

My next repair section made -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0777.jpg

 

Welded into place, this section over laps the first piece I made slightly to make sure it has plenty of strength -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0778.jpg

 

Last but not least there is a small infill piece required for the very end of the inner sill -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0779.jpg

 

And welded into place, also lapping onto the previous repair section, you can see the extent of the area I've replaced here, some of the welds still need to be dressed back but it's nice and solid now and gives me a good bit of metal to weld my outer sill repair onto -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0780.jpg

 

With the inner sill repaired I was able to make a repair section for the outer sill now that I had something solid to weld it to -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0781.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0782.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0783.jpg

 

With that now sorted it was time to look further back on the car to see what needed repaired next, first up here's a hole in the front end of the rear chassis leg where the front mount for the rear axle is ocated -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0784.jpg

 

Further back there was a split appearing on the chassis leg near where the subframe bolted up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0785.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0786.jpg

 

Various other splits and holes on the drivers rear chassis leg, mostly at mounting points too -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0787.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0788.jpg

 

Back to the start of the rear chassis the hole I'd found earlier was much bigger with a little bit of prodding -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0789.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0790.jpg

 

Slightly further back there was another hole and some very crumbly metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0791.jpg

 

I knew I'd have to lower the rear axle to get access to weld some of these bits, what I found though was that this mounting plate had been welded to the chassis when a previous plate was fitted so it had to be ground off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0792.jpg

 

The extent of some of the rust further back on the chassis is more obvious now too -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0793.jpg

 

With the axle dropped down slightly you can see the full extent of the rust at the front end of the rear chassis leg, this rust starts basically right behind the inner section I'd just repaired so I know I have good metal to weld to -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0794.jpg

 

Starting with the hole at the front, I cut out the rust and made the hole larger in the process -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0795.jpg

 

Repair plate cut to size -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0796.jpg

 

And welded into place, not handy when it's right next to the fuel tank -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0797.jpg

[ganges]

cracking updates, mate, and a good job, bloody hell you got some rust issues there nice to see this coming along though, keep up the good work:thumb: Edited September 7, 2013 by ganges

[lee grout]

Think the repair bill will be a bit of a surprise Good work though. As soon as you look for rust its like opening a whole can of worms.....tin worms lol

[escortlew]

Once again a fantastic update Gary!!!

[blacksofstichill]

cracking updates, mate, and a good job, bloody hell you got some rust issues there nice to see this coming along though, keep up the good work:thumb:

 

Cheers! Some pretty big rust issues right enough but luckily there was still some solid metal left to weld to.

 

 

Think the repair bill will be a bit of a surprise Good work though. As soon as you look for rust its like opening a whole can of worms.....tin worms lol

 

Thanks, yeah, the deeper you dig the worse it gets but at least it will be solid when it's done.

 

 

Once again a fantastic update Gary!!!

 

Cheers Lew!

 

 

Moving further back and onto the next hole now, this area is up from the end of the inner sill and really the whole of this area was rotten as was the inner rear wheel arch at the bottom -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0798.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0799.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0800.jpg

 

First repair plate made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0801.jpg

 

And tacked into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0802.jpg

 

At this point my Camera Batteries died but I had to crack on with the work that day, so my next photo is taken the following morning, the inner rear wheel arch was repaired at the bottom, there's new metal welded in basically right around where my finger is -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0803.jpg

 

Repair plate made for the last bit of the underside of this area -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0804.jpg

 

And welded into place, lapping my previous plate below it and tied in to the plates on the inner wheel arch -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0805.jpg

 

Moving further back again, this is the split in the chassis where a previous plate had been welded to the mounting bracket, the metal is all solis, it just needs a plate over the split -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0806.jpg

 

The large weld to the left has to stay as it is, it is the edge of a previous plate welded up the inside edge of the chasis leg and the weld is right next to the tank -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0807.jpg

 

Repair plate made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0808.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0809.jpg

 

Looking from the rear axle forwards you can see the extent of what has been repaired, the entire rear end of the inner sill and the front end of the chassis leg have been reconstructed in new metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0810.jpg

 

No rest for the wicked, here is the chassis leg just behind the shocker after some poking with a screwdriver, not pretty -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0811.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0812.jpg

 

At this point the Clarke Welder I'd been using decided to die, I think the sight of the chassis legs were just too much for it, it hadn't been producing a "nice" weld without constant adjustment of the settings and it got to the stage it just wouldn't weld at all. So, I brought round my Dad's Murex MIG which I'm much happier using -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0813.jpg

 

Not that you'll see a great deal of difference but I also re-welded some of the last seams I'd done, just to be on the safe side -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0814.jpg

 

Getting back to the chassis leg, I cut out the rotten areas -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0815.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0816.jpg

 

Despite the large hole this left me with, I was lucky that some previous plating on the Chassis had been done well and with good metal so it gave me something I could weld to safely, first repair section is just a small plate -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0817.jpg

 

This was welded up the inside edge of the rail -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0818.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0819.jpg

 

Second repair plate made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0820.jpg

 

This one is also for the inside edge, lapping my previous plate this one finishes off the insde edge of this area -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0821.jpg

 

Third repair plate made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0822.jpg

 

This one tucks under my last plate and finishes off the bottom of this area -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0823.jpg

 

I also welded it to the strong inner skin of the area where the subframe bolts up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0824.jpg

 

Fourth repair section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0825.jpg

 

This was just a small plate welded to the underside of the brake hose bracket -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0826.jpg

[blacksofstichill]

Fifth and final repair section for this area made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0827.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0828.jpg

 

With this plate welded in, that's all of this hole replaced with new metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0829.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0830.jpg

 

Just back from this area I found a thin bit of chassis which I easily made a small hole in, this is all good strong metal but I think it has been ground very thin in that one area when a previous weld had been ground back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0831.jpg

 

Repair plate made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0832.jpg

 

And welded into place, I made the plate cover a larger area than the hole in case other parts around there were equaly thin -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0833.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0834.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0835.jpg

 

Welds ground back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0836.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0837.jpg

 

Further back on the rail there was another small hole -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0838.jpg

 

I found that the metal was very solid around that area and the hole was still quite small even after some poking with a screwdriver and some grinding, it's hard to photograpth this area with the subframe in the way -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0839.jpg

 

I decided that instead of making a small plate just for that area I'd make a plate to go the full length of the inside edge of that area -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0840.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0841.jpg

 

Looking underneath on the rest of the drivers side the only other dodgy area is a small bit fof rust in the rear footwell, this will be left until later when I have the full interior out though and will be an easy part to repair -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0842.jpg

[blacksofstichill]

With the drivers side chassis leg all sorted I removed the back bumper to see what was lurking beneath it, the panel here had split and was very rusty -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0843.jpg

 

As you can see, it was so weak it easily pulled back by hand -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0844.jpg

 

This area is double skinned, the inner and outer rear quarters are joined along the bottom edge here but there is a gap between them, albeit very small. So, to start with I cut off the rusty area of outer skin -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0845.jpg

 

With that revealing more rust on the inner skin, I also cut the inner skin out too -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0846.jpg

 

The corner of the area where the vent flap fits in was also rotten with a hole through to the inside of the boot -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0847.jpg

 

To get myself started here I made a small repair plate to replace the missing flange near the bottom of the vent flap hole -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0848.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0849.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0850.jpg

 

Next up I made another small repair plate to fill in some of the missing area below the vent flap hole -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0851.jpg

 

Welded into place, there are still gaps around it but my other plates fitted on the outer skin later on will sort that out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0852.jpg

 

Rather than just repair this area as a single skin and seal the two halves further back in the rear quarter I repaired both the inner and outer skins individually, starting with this panel for the inner skin -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0853.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0854.jpg

 

Then I made an infill piece to make up the gap -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0855.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0856.jpg

 

Looking from inside the arch, I still have it all to weld in there and areas to clean back but you can see how and where my plates have been fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0857.jpg

 

Next I made a panel to start replacing the outer skin -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0858.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0859.jpg

 

Welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0860.jpg

 

Repair panel made for the top edge of the outer skin -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0861.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0862.jpg

 

Infill piece made which will complete the outer skin -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0863.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0864.jpg

 

Welds dressed back, if this was a panel which was on the outer bodywork you could carry out a similar repair but joggle/step back the edges of the repair plates so that the outer face sits flush with the existing panel rather than above or behind it as it does here -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0865.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0866.jpg

[scottybo]

entire cars gna be made of weld soon

[scottg17]

Looks as bad as my GTI did..... I nearly fainted at the sight of the amount of welding it needed and ended up stripping it... Great to see you are sticking with it

[blacksofstichill]

entire cars gna be made of weld soon

 

Oh Yes, and there's more to come yet!

 

 

Looks as bad as my GTI did..... I nearly fainted at the sight of the amount of welding it needed and ended up stripping it... Great to see you are sticking with it

 

Cheers! It needed a lot more welding than was anticipated but at least we know it's solid once it's done.

 

I looked further back and found the edges of the vent flap hole crumbling away in some areas -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0867.jpg

 

So I cut the rotten bits out, the shape of this panel doesn't make it easy to repair -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0868.jpg

 

First repair panel made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0869.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0870.jpg

 

Second repair panel made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0871.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0872.jpg

 

With the welds roughly ground back you can see I still have the awkward little corner still to do -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0873.jpg

 

This is where it gets fiddly! Small plate made up to form the curved flange in the corner -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0874.jpg

 

Welded onto my other repair sections on either side -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0875.jpg

 

Another very small plate made, this one will make up the flat back face of the panel, welded abover the small curved piece -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0876.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0877.jpg

 

The last plate to make is one to form the outer radius in the corner -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0878.jpg

 

With that welded into place, that's this area all solid again -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0879.jpg

 

After some careful grinding these pieces which have been repaired really start to take shape -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0880.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0881.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0882.jpg

 

Viewed from inside the boot -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0883.jpg

 

Back onto the underside of the arch I was almost ready to clean and weld this area here -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0884.jpg

 

Until I looked further up and saw this, the filler neck isn't attached to anything as the surrounding panel has rotted away, very common problem indeed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0885.jpg

 

Before I let myself loose on that I primed and seam sealed some of the repairs I had done earlier, starting with the outer sill -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0886.jpg

 

Then the inner arch at the end of the sill -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0887.jpg

 

Chassis leg behind the shocker -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0888.jpg

 

Inner Sill and front of the rear chassis leg -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0889.jpg

 

Underside of Chassis leg at shocker -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0890.jpg

 

Inner side of chassis leg toward the rear of the car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0891.jpg

[escortlew]

Once again Gary - epic - a lot of work time and effort - look forward too the final piece of art!