Escort RS2000 4x4 2.0 Turbo Conversion

[lee grout]

You must have shares in that seam sealer Nice work on the vent into the boot.

[NielsF1]

Wow, glad you're solving the rust issue...!

 

Well done!

[blacksofstichill]

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

 

Cheers Lew!

 

You must have shares in that seam sealer Nice work on the vent into the boot.

 

Thanks, the vent hole was quite a fiddly bit to sort! You can't beat a bit of seam sealer!

 

Wow, glad you're solving the rust issue...!

 

Well done!

 

Thanks, there's even more rust yet to come believe it or not!

 

With all of that tidied up I pulled the filler pipe out of the way to see how bad the rust was here -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0892.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0893.jpg

 

I ground out all of the rusty areas unti I was back to good clean metal, this is now a massive hole compared to what it should be -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0894.jpg

 

Repair panel cut but not shaped yet, I used a holesaw to cut out the centre hole -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0895.jpg

 

Can you see how this is going to work -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0896.jpg

 

After a bit of cutting and folding I had the repair panel roughy the right shape for the job -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0897.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0898.jpg

 

Welded into place from the outside -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0899.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0900.jpg

 

And also fully welded from the inside too -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0901.jpg

 

While I was in here I also seam welded the inside edges of my earlier repair panels -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0902.jpg

 

That means that all of my repair panels on the rear quarter are fully seam welded inside and out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0903.jpg

 

Fixing hole drilled in the filler neck panel, the pipe isn't bolted in place here hence why it's not sitting centrally, you get the idea though -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0904.jpg

 

With this corner now complete I primed and seam sealed it all inside and out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0905.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0906.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0907.jpg

 

The inside of the boot could do with another coat of sealer to smooth it out more after this coat has set -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0908.jpg

 

All I use to make these repair panels is this electric shear to cut the sheet metal -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0909.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0910.jpg

 

And this basic folder -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0911.jpg

 

Obviously a hammer and an anvil are sometimes used too!

 

moving on from the drivers side I started by checking out the boot floor and spare wheel well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0912.jpg

 

The spare wheel well had a lot of rust but no holes in it, so I started to clean off the surface rust to get a better idea of how solid it was -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0913.jpg

 

The pitting of the rust was very deep and the remaining metal was very thin, although you can't see it in the photos there were lots of tiny holes also starting to appear -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0914.jpg

 

Chipping off some of the scaley rust also led to more pinholes appearing and again, the metal was weak and thin -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0915.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0916.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0917.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0918.jpg

[sidrick]

That's some graft you're putting in! Nice updates.

 

Any reason you/the owner didn just go for another shell?

[blacksofstichill]

That's some graft you're putting in! Nice updates.

 

Any reason you/the owner didn just go for another shell?

 

Thanks, some of it has been quite a challenge but I've enjoyed it! With hindsight, another shell would have been a good idea but it's finding one (particularly a 4x4 one) that isn't also going to need welding at a decent price that isn't so easy. That and the fact that the owner wanted a black one in particular (this one was painted black in his ownership) made it a bit more justifiable to use this one. Mind you, when you see some of the rest of the welding that is yet to come you'll think we are mad!

 

Since it was like this all over the bottom of the well it meant there was no good metal left to do any localised plating and in any case it would mean that the areas not plated at this time would only end up having to be done in a year or so. So, without further ado I cut the bottom of the spare wheel well out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0919.jpg

 

I also cut out some areas of the side of the well which were also rusty and weak -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0920.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0921.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0922.jpg

 

So this is what I was left with -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0923.jpg

 

Starting with repairing the sides I cut a plate for the left hand side -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0924.jpg

 

I then shaped it to roughly the curve of the bottom edge of the well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0925.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0926.jpg

 

Welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0927.jpg

 

On the right hand side there is a much larger area to plate on the side of the well but I start off with the mostly straight section first -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0928.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0929.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0930.jpg

 

Welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0931.jpg

 

This is what I've got left to fill in on the right hand side -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0932.jpg

 

Because it's all on a curve and over a large area I decided to make this up in 3 sections starting with the middle section -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0933.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0934.jpg

 

Next section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0935.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0936.jpg

 

Last section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0937.jpg

 

And welded into place to complete that area -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0938.jpg

 

Welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0939.jpg

 

Since you can't buy a spare wheel well repair panel I have to make my own one up, rather than just make it flat right along the bottom I decided to make it recessed in the middle similar to what it was originally. This was partly so it woul look better but mostly to make it a stronger job So, I cut a round plate for the centre recess -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0940.jpg

 

I then formed an angle right around the edges of it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0941.jpg

 

With it laid over the top of the original panel you get an idea of why I've shaped it in that way -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0942.jpg

 

I then needed to make the outer circle to fit around the centre, since it is a large area I made it in two halves, here is the first half cut out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0943.jpg

 

And again, I formed an angle on the edge of this -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0944.jpg

 

And then I welded the first half of my outer circle to the centre panel -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0945.jpg

 

With that laid into place you can see how it will work -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0946.jpg

 

Second half of the outer circle cut and formed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0947.jpg

 

And all welded together -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0948.jpg

[Hezz]

Did you think about making the spare wheel well big enough to fit a proper wheel rather than the 4x4 pram wheel ?

 

Great work as always

[blacksofstichill]

Did you think about making the spare wheel well big enough to fit a proper wheel rather than the 4x4 pram wheel ?

 

Great work as always

 

Cheers! I didn't make the wheel well any bigger, I just replicated what was there but if I hadn't been able to save any of the original sides and bottom edge of the well I'd have probably made it bigger while I was at it.

 

With the 2 panels side by side you can see the recess I've made in it is similar in size and depth -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0949.jpg

 

Welds all dressed back on the underside before fitting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0950.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0951.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0952.jpg

 

Welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0953.jpg

 

Spare wheel retaining bracket cut off the original panel -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0954.jpg

 

And welded onto the new one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0955.jpg

 

Looking at the rest of the boot floor, there were a couple of small holes and some areas of surface rust, none of these were very serious or big but they're best to be plated now while the metal was still good -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0956.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0957.jpg

 

First area ground back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0958.jpg

 

Plate cut to suit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0959.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0960.jpg

 

Second area ground back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0961.jpg

 

Plate cut to suit and welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0962.jpg

 

Last area cleaned back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0963.jpg

 

Plate cut to suit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0964.jpg

 

Welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0965.jpg

 

All welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0966.jpg

 

Onto the seam sealing now, some of these areas will get a second coat tomorrow to smooth them out further at the seams, starting out with the underside of the spare wheel well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0967.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0968.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0969.jpg

 

The plated areas on the boot floor -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0970.jpg

 

And finally inside the spare wheel well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0971.jpg

[sidrick]

Quality graft as usual. Loving all the photos.

[blacksofstichill]

Thanks, there's still plenty of pics to come.

 

With the spare wheel well sorted out I started looking at the passenger side of the boot floor, it had already been plated in the corner of the boot and at the bottom of the inner arch -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0972.jpg

 

To be sure the plates were solid I cleaned them back and dressed the welds a bit too -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0973.jpg

 

However, it wasn't all good news, I could see daylight inside the back quarter -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0974.jpg

 

The hole comes through to the outside here -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0975.jpg

 

There was masses of sealer on the inside of this area -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0976.jpg

 

The hole is getting bigger -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0977.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0978.jpg

 

Because this whole area is rotten where the bumper screws on I'll have to cut it off completely rather than plate in repair sections, so to be sure I make my repair panel the correct shape I'll make it all off the car, mark where it needs to go and fit it as one piece once the rotten area is cut off......so I started making this bit first -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0979.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0980.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0981.jpg

 

Checking it for fit -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0982.jpg

 

Onto the next bit -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0983.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0984.jpg

 

Second section welded to the first piece and checked for fit on the car -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0985.jpg

 

Onto the next piece of the puzzle -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0986.jpg

 

You'll notice that there is a split in the rear quarter above the bumper line but my repair panel will not cover that part, this is intentional as if I repair any of the outer bodywork such as this it means that Olly basically has to get the car painted as soon as I'm finished with it. By keeping all of my repair sections out of site it means that no paintwork is needed immediately but whoever makes the bodywork repairs will have good clean metal below the bumper line to weld in small repair sections when the time comes -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0987.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0988.jpg

 

Another piece -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0989.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0990.jpg

 

Another trial fit and this time I mark on the body where the edges of my repair panel should go so I can line it up in the correct place once the rotten section is cut off -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0991.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0992.jpg

 

Inner arch area cleaned back -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0993.jpg

 

Rotten outer section cut off -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0994.jpg

 

New section welded into place -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0995.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0996.jpg

 

Welds dressed back -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0997.jpg

[blacksofstichill]

Viewed from the inside of the arch you can see where I need to fill in the gaps with new metal -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0998.jpg

 

Repair plate cut -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0999.jpg

 

And welded into place, I also rewelded an existing plate along the bottom edge as it was loose -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01000.jpg

 

Another plate cut -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01001.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01002.jpg

 

Priming and seam sealing this area inside and out now -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01003.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01004.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01005.jpg

 

Looking further forward at the rest of the inner arch more holes were revealed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01006.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01007.jpg

 

 

Before I tackled those I resealed the existing plates inside the boot -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01008.jpg

 

Inner arch holes viewed from inside the passenger back quarter -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01009.jpg

 

 

Rotten areas cut right out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01010.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01011.jpg

 

Instead of struggling to make this repair all with one plate I did it in 3 sections, first one here -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01012.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01013.jpg

 

Second one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01014.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01015.jpg

 

Third one completes the repair in this area -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01016.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01017.jpg

 

 

There was also some rot at the bottom of the inner arch where it meets the inner sill -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01018.jpg

 

asessing the damage, this area will be left until the inner and outer sills are looked at-

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01019.jpg

 

Moving onto the rear chassis rail, more rust is evident with splits showing in the leg -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01020.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01021.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01022.jpg

 

Some of the loose rust chipped out of the way in the first area to be repaired -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01023.jpg

 

Surrounding area ground back to good metal, because the inner section of the chassis is sound I'll be able to weld my outer plates to it to add extra strength to the job -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01024.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01025.jpg

[lee grout]

Well...............................

 

1: Great work as ALWAYS.

 

2: Surely it would of been cheaper for the guy to find a clean shell for a couple hundred quid!? I bet your well into that sort of figure with repairs and I bet there's still plenty to go!

[Naylor2006]

Well...............................

 

1: Great work as ALWAYS.

 

2: Surely it would of been cheaper for the guy to find a clean shell for a couple hundred quid!? I bet your well into that sort of figure with repairs and I bet there's still plenty to go!

 

Top top work, love following this.

 

Its a 4x4 isnt it, there would be limited numbers and at a premium price.

[JC]

A really good read, good work, and loving all the pics

[sidrick]

5 days without an update? Unacceptable!

 

I assume you're too busy cutting and welding though

[scottybo]

5 days without an update? Unacceptable!

 

I assume you're too busy cutting and welding though

 

i doubt there will be much original metal left by the end!