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Project: Tim mexico


	Hi Tim if you are reading this you must have got on to the website ok if you are not reading this please let me know. Here she is still in the same place you saw it last all the boxes have arived ok talk soon mate take care Mick.


Hi Tim here she is all stripped and all the parts tagged and put away. We are all feeling good about this one


	Here is the inside with all the sound pads stripped of we are still feeling good.


Here is the underside there are a few parts we are not sure about


	The underside with the underseal removed


The inner wings are quite bad the wings will have to come off


	Both sides


The strut supports are shot as well both sides


The chassis needs a bit of love,


	Where the antiroll bar mounts needs plating


The chassis has gone both sides here


Both floors could do with changing


	There are a few repairs here and there it is good to take them off and check there is no rust behind them we normaly find plates have been fitted over the problem.


Both rear wheel arches are quite bad we will have to change the inner wheel arch lip.


Spare wheel well and tank well need sorting


	The floors have been patched


Were the roll cage has been fitted the floors are rotten


	Slam panel ends need changing


Heater bowl will need to come off and be repaired


	Inside as well


The hinge brackets will need to come off and upper bulk head repaired


	Windscreen appeture repairs


	The cill needs a repair or two Sorry to be the bringer of bad news Tim but this shell will need a lot of fab, of the top of my head I think you will be looking at a sum of around 6k - 8k + vat to sort the shell out to a good standard if you want me to work out a fab list and an estimate of time please let me know. Talk soon mate take care Mick.


Hi Tim we have been removing all the seam sealer today ready for the big chop out on Monday.


	Most of the old seam sealer and sound pad goo is now of.


	Here is Oddie starting to remove the rear wheel arches


The car has a few jigs on it to keep its strength


	This is were Oddie has been for most of the day it's a shit job but it has to be done. I will get some better pictures up next week once your car goes into the fab shop we are going to re-blast some parts on Monday then it's into the fab shop Thats all for now mate take care Mick.


Hi Tim we have re-blasted the shell and chopped out a few bits we are waiting for the delivery from express all the panels will be in on friday so we will be able to make some way forward.


	we have taken the rust out of the rear tubs when we get the arches we can finish of.


	we can't remove to much as this would weaken the shell.


	We have made extra braces to keep everthing together.


Here is the chassis cut out and ready for the new one


	We had the chassis legs in stock so we have fitted one of them we will leave the other one until we get some strength back in the car.


Thats all for now mate take care Mick.


	Hi Tim A big hole in the floor here it is all chopped out and prepped for the new floor.


	Here is the chassis rail painted with zinga. Zinga was invented to stop ships rusting it is 96% pure zinc and it is part of the galvanic family basicly it's good stuf.


Seat belt mounts.


	One side of the chassis welded in.


All ground up ready for seam welding


The chassis leg seam welded


Sorted


	This car will be re-made by the time we finish


	This is the first time we have fitted these panels they are quite good.


We have tried to keep the lines in the floor were they were so the car will look like a factory car.


	Unlike this


It's a bit of a jigsaw at the moment


	That's all for now I will get more pictures up middle of next week. Take care mate Mick.


Hi Tim just a few more of were Oddie is with your car.


One side of the bulk head top fitted


	Now on to the inner wing top


After some jigery pokery the wing top is clamped in place ready for welding


	Welded both sides


	The wing closing plate fitted


It's looking strong on this side now


	New floor nearly welded in. Oddie is seam welding the panels as he goes. Thats all for this week mate with a bit of luck Oddie will be in next week so we will crack on. Take care Mick.


Here we go this side of the car is nearly sorted.


	This looks a bit suspect


So we have made a new part before we open it up.


	This is one of the areas the mk2 always fails in where the anti roll bar fits.


All chopped out and the new one fitted.


	Here we are with the other floor chopped out.


The chassis needs a bit of lovin.


	Chopped out


All parts have been either zinga'd or copper sprayed.


	All plated up.


Cleaned up looks like a brought one


	A new piece on the end and we can fit the new chassis leg.


All the inside parts are coated with zinga (Oddie forgot to take a photo)


	The underside is looking something like now.


	The inside looks like a car again. Thats all for now I will get some more pics up mid next week. Take care mate talk soon Mick.


Hi Tim here we are mid next week anyway here are some pics for you. By the way billies should be blue.


	All parts have been blasted before coating.


	The axle springs and some other parts have been zinc coated and powder coated.


	Here she is looking like a new car


But we are still chopping bits of


	New bulk head top plate fitted


A repair to the a post.


	New kick panel fitted.


The inside of the new kick panel and bulk head top plate


	Powder coated parts ready for wrapping and storing


The new boot floor all welded in looks great


It is really coming together now.


	This is a repair to the lower part of the inner wing were the roll bar mounts. Thats all for this week mate have a good weekend talk soon take care Mick.


Hi Tim we are really getting on with it you will be glad to here, as you can see this is the new wheel arch fitted Oddie has fitted the complete arch and he has rolled the arches as well.


Here is inside the boot on the drivers side all looking chummy.


And the passenger side also looks the part.


	This side is all sorted now.


When we looked at the cills it was not really worth repairing them so we have fitted two new ones. we have had the doors on to check the gaps they all look good.


	Checking the gaps on the front end. The car is really looking well now. Thats all for now mate talk soon take care Mick.


	Hi Tim Here is the new fire wall.


The rear seat has been fitted to make sure it still fits.


	All the front end is complete.


Bulk head support plate fitted


	We have done the mods for the rad at the top and bottom.


Mocking up the fuel tank. We spent 15 mins looking for the tank base. This is the first tank I have seen that fits to the boot floor good idea.


	A little bit of tinkering and the rad now fits.


Seat supports fitted and the welds cleaned. Thats all for this week mate I will sort some more out next week I am working on site from Wednesday so I will try and get some up before then if not I will post some from home on Saturday. Take care Mick.


	Hi Tim sorry I did not get any pics up on saturday I was working on site we are blasting big tanks for honda it's a masive job and the welders keep puting us behind and we are on a dead line. Anyway Oddie has been busy on your car here is the boot all done all the fixing points are weld nuts.


Panhard rod tower fittet.


	Pedal box in we had to make some new fixings as the pedal box did not fit, good job we checked.


When we came to fit the heater there is some slight damage to the heater unit and one of the switches is broken.


	The heater box fitted. We will fit the engine and gear box to check for clearence and gearbox mounting.


Inside the heater plenhem painted.


	New gussets fitted


Oddie has started on the roll cage I don't know were he is at on the roll cage I will let you know.


	New lower rear panel fitted.


Both cills have been replaced.


	Holes welded up and cleaned. Thats all for this week I will let you know when there will be some more but if I don't have any before christmas have a great christmas and an evan better new year thanks again for your help and support this year take care mate all the best Mick and Nikki


Hi Tim I hope your x mas was a good one here are a few pics to keep you going. Engine and gearbox fitted we have made sure the rad mod is ok.


	We have modified the gearbox mount so everything fits just nice now.


	Here is she is in the paint shop.


The roll cage fitted we have built some boxes to stand it on so that it is a good fit to the car.


	First job is to do a panel fit. Then we have blocked up the bonet to try and make it fit a bit better there is no cross bracing on the back of the bonet so I dont think this will last.


As for the paintwork we are giving the car a good bake to see if there is any problems with the paint that is on the car. And to try and make the carbon panels fit a bit better. We will go for a bare metal respray just to be sure.


Thats all for now tim I will get some more up next week and you will see some action on the paintwork. For protection I think a course stone guard will be fine as you intend to use the car, we will acid etch the car then seam seal all the seams then stone guard the underside then paint over the stone guard. As we are using a course stone guard this will save time on preping the underside and we can spend more time on the parts you will see. hence the full bare metal respray. Talk soon mate all the best Mick.


	Hi Tim here we go, the car has been fully stripped and here we are checking the gaps one more time.


We have done some tweeks on the doors to make them fit.


	The shell has been blasted again to make sure that it is fresh before the etch primer.


The etch we use is a wash etch it is very thin and gets into all the nooks and cranny's it is a two part active acid etch.


After a good bake we have scotched the shell.


	Any repairs will have a skim of filler in them.


Inner wing after filler.


Beacause we are using a course stone guard we can apply the seam sealer quite thick normally we rub most of it of if we are just painting the underside.


	Here you can see the door is a bit rusty.


Action shot.


	All better now Oddie has replaced the grotty metal.


All the seams are sealed we work the sealer in to the joints then smooth the sealer off we do this on all the joints inside and out. That's all for now I will get some more pics up next week. Take care talk soon Mick.


	Hi Tim I have an hour spare so I thought I would post a few up for you. Here is the shell all seam sealed up.


After a bit of masking we have used a product called dp 40 this product is a surfacer and an adhesion promoter.


	After a bake we then apply the stone guard.


	Here is the other door Oddie has chopped the rust out.


And welded a new strip in.


	Were do you think this bit is ? Tell you later.


We are now prepping the inside, engine bay and boot. All the unused holes are taped of using ali tape. (the devil is in the detail )


	Every seam will be sealed we make a nice neat job of the areas you will see and a few you won't


After sealing we put a coat of dp 40 over all the sealed areas ( so most of the car then ) Oh yes the mistery part it is part of the fire wall we have to seal up the c pillers so that the hole boot is sealed from the cabin. This car is sealed better than the group n cars from prodrive don't ever bur one of them !! Well mate it's 430 now and I have to be going talk soon take care Mick.


	After a bit of fafing here we are in primer we use a good two pack high build primer from PPG.


After a good bake we apply a guide coat when the guide coat is rubbed down you can see any inperfections in the primer as they stay black.


	Here is the engine bay all rubbed down all the breakthroughs are coated with DP 40.


Here is the underside ready for paint it has been scotched all over then de-greased.


	The sound deadening pads fitted they also had a coat of DP 40.


This is the inner wing after two coats of top coat the colour is great it has a very slight blue tint it is called frozen white, my car is racing this year in the lma saloon car championship I am thinking this is the colour it will be after it get a scrape.


This colour just looks so fresh this car will be an absolute stunner, the boys are realy doing a good job and they are into making this one special now that we have some paint on it even though it's a job to see in the photo's it realy does look owesome.


	The boys are applying the finel coat now they have put 12 ltrs of top coat on it so far. Thats all for now mate it is 420 now and I must get ready for tomorrow I am of mobile. Hope you like the pictures talk soon take care Mick.


Hi Tim This is how the car is left every night any bare metal parts are etch primed.


	Then when we start work we D.A. the parts we will be working on.


If there are any major repairs we put a skim of fibre glass to stop any cracking later on.


	Then we use filler as a surfacer it looks as if the car is full of filler but it is a very small skim as you can see we fit the doors then we can block through the doors to the wing and qtrs making sure of a good flat surface between all the panels.


We then use a pollyester filler primer on all the main panels with the polly we can start to get the body lines you can tell our cars beacause the body lines are really sharp.


	The door gaps are looking good.


Here the car is in guide coat this is over the polly filler primer.


	This all gets blocked by hand with the doors on.


Then the doors are removed. Question do you want the front bib spoiler fitted back on ?


	All rubbed down ready for primer.


	After that we have primed the car and the doors then it gets a good bake and left for a few days to let the primer settle.


And here we are now all ready for the doors to be refitted and block the car once more this is the finel blocking after this any breakthroughs will be primed with DP 40 then on with thye top coat so by the end of the week it should be going white as long as the snow goes away. Talk soon mate take care Mick.


	Hi Tim Sorry for the delay but here we are the car has been left to settle guide coated and is all ready for a good rub down!


	The boot has already been painted but we have to repair the spit marks this is were we support the car on the spits as you can see we have repaired the holes and filled them primed them and dp40 all ready for some more white


The rest of the car is ready for some top coat all the dark patches are dp40 any breakthroughs are coated with dp40


We seal all the seams on the outside including the wing to a post.


	We even seal under the gutter rail this is attention to detail gone mad but it does make a differance.


After we have sealed the seams we let them dry then coat them with gess what yes dp40


Here you go a bit of white stuff going on here


	Time for a close up as you can see all the prep has paid of the nooks and cranies look like plastic they don't look like they have been painted.


We have kept all the original features


	We have just been awarded the best body work and paint job by classic ford for mark hendy's rs2000 I think yours will be better than that one it looks stunning the white looks so fresh. I want one.


We will leave the stickers for now I think it would be better to fit them at the end of the build just incase we have a scratch or a knock. Hope you like the pictures I think you would like to see it in the flesh I will get some more after the unmasking ceremony.


	Hi Tim I missed the unmasking so you will have to look at the next few pics of masking.


More masking


Here we go some results at last.


	What can I say it looks owsome hope you like it if there are any details you would like to see just let me know mate. Neal and I have started sub assembling the front end and Saturday we will be bolting things on the shell I have sorted the brake lines and fittings I have all stainless steel fittings for the brakes exept the lines they will be copper with a twist I looked at stainless lines but I think they would break the bank at £24. per mtr and a tool to bend them. I will get some pics up next week I am back on the mobile job at some point so I will keep you informed take care Mick


Hi Tim These little blokes have given me some problems they look ok but if you look at were they mount one set of holes are inside the chassis you can see better from the picture below


	I thought that a new pair of bushes and some new brackets would do the job but oh no life is not that easy. When I fitted them the bushes could not be clamped they were to far apart.


After some head scratching I decided to cut of the thredded part and start again.


	All powder coated lovely.


Now they fit beautifully with the new brackets and bushes.


	And as you can see all the holes inside the engine bay as they should be. We have fitted them with jot bolts for now a bit later we will do a ss bolt list and change them.


Rear axle all built and fitted. Including the lsd.


	Here are the brake pots I think they look good here hope you do to.


This is where the rear brake line comes from once the carbs are fitted it will not be visible.


	All the brake pipes are in place (exept one for the rear) and only one in the engine bay.


Here is the secret we run them inside the bulk head. So no brake lines running all round the engine bay neat hay.


	This is were they come out inside the wheel arch where the brakes are all the bulk head fittings are stainless steel.


	Hi Tim your car has made it's first jurney it is now in the build room (it went there on go jacks)


Look the engine is in.


	A few more bit's and bob's going on


Axle all in I need to order some bushes for the two link brackets and then the axle is finished.


	The calipers need some spacers making so Neal is on the case we will have them on Saturday. I have brought some A N bolts to mount them with.


	The alternator seems to be the wrong one but with a bit of jigery pokery I think it will be ok I will have to get a smaller belt though.


Tomorrow we are fitting the coil pack and sorting the oil cooler and pipes fitting the calipers.


	Hi Tim just a few more to keep you going this is the rear brake line once the carbs are in it will not show.


This is were we have mounted the coil pack all the leads seem to reach and it will look good when finished. Has this engine run on this set up if so where does the trigger wire go to is it the rev counter?


	We have put the oil cooler here it is mounted on rubber bushes so if you have a bump it can move. I would like to make the pipes for the oil cooler we use prolight hoses amd bulk head fittings they look the part and once done will last forever. You can just see one on the oil tank of Jack. They are black the same as I used on Jack.


From the front it looks like this.


	Here is the ECU the parcel shelf will still fit and it is out of the way. You can still get to the comms lead. If you have any wiring details for the coil pack it would help. Oh well it's 1 30 now and Nikki will be ringing me to see where I am soon so I will wish you a good weekend and I will try and catch up next week mate take care Mick.


Hi Tim yes we are still here Here is the crank sensor wire we have rapped it in some heat sleaving for extra protection.


	The wireing looking good.


We have piped up the oil cooler after some mods to the cooler converting it to dash 10 fittings and with the new sandwich plate all the fittings are now dash 10 and looking good. The bracket on the far left is for the oil cooler it is attached to the car with a rubber mounting


	They run through the front bulk head here


And come out here. You can just see one of the rubber mounts for the oil cooler


	Here is the new sandwich plate as you can see the fittings are not black these are some I had in stock and as they will be covered by the carbs we have fitted them and they are on the house.


The car is looking realy smart now the more we put on the better it looks I know it has cost the earth but I think you will be so happy with the car when you see it.


	The fuel line is just about finished now we have run a hard line under the car all with proper fittings. I have fitted a new regulator with dash 6 fittings hope thats ok it makes the job so much neater if all the fitting are the same and I don't like hose clips they look pants and I know you like neat.


Here is the fuel line running along side the brake pipe.


	Rad in and staying in


Looking the part


	I hope you like this it is the way I did kermit and so many people comented on it. I have used stainless steel wire.


	Your cool tape I have used on some heat sheild under the floor.


There are many bits finished that I forget to photo for you like the brake hoses.


	The new sender mount all sorted.


The new regulator just need a few bits for the pump and carbs so we can finish the fuel system. That's all for now mate talk soon take care Mick.


	Hi Tim Here is the little devil it looks the same but has fittings for dash 6


And it lives here the fuel system is now compleat just need to wire up at the drivers end I have run the wire so no problem.


	A few parts being painted the rear bumper and seat frames are on the other side of the booth don't worry we are not just painting one of the front bumpers


A new battery all wired up and ready to go


	We have used a bulk head fitting for the live wire here it is in the engine bay. I have unpicked the loom to see what was going on there were wires that went half way down the loom then turned around and came back so I have had a chopping sesion and made it a bit more sensible


Here is the bulk head fitting inside the car


Starting to look the part spot light brackets fitted I just need to make a loom for the lights.


	New two link bushes fitted


I have had to weld some bushes in the roll cage to pick up the seat belt mounts. There is not a lot to show you this week but all the little things we have done have taken a long time to do at this stage it always seems to go on when we are sorting out small problems it just saps the time but it has to be done. Well thats all for now mate my car has it's first race next weekend so I will have to sort that out tomorrow just a few things to do I am testing it at malory park on Wednesday (Nikki does not know yet so I will tell her after a vodka tonight) Take it easy and be lucky talk soon mate Mick.


	Hi Tim hope mickey is ok and the trip was a good one look we have windows.


We have had a few problems with the wires but I think we have it sorted as I said above this part of the project seems to go on forever but we are making progress it's a case if fitting the small parts and tidying things that have been fitted.


	Heres one


We are getting the wiring sorted now we have wired up for 4 spots on two switches.


	Now we know every thing works I can wrap it up.


Under the dash is looking a bit full now I just have to tidy it up.


	New battery


Looking nearly there on the outside. After the weekend I will get some more pics up, we are going to start the engine on Saturday so that will be a leap forward as long as it does not give us to many more jobs.


	I have had a nightmare sorting out the oil presure the guage is a wierd thred and the ends are to small to crimp a pipe on to so this is the only way I can sort it if I have any time I will re-visit this one I don't like ends like this they tend to fail when you are a long way from home.And not having a warning light it is a worry I am asuming that the engine has not been run in so I will use some cheap oil, if you use a good oil it makes it hard for the rings to bed in so after the rolling road the oil will need changing. talk soon mate take care Mick.


Hi Tim this is the moment we found out there was no sump plug.


	The sump plug is a weird one normaly they are m14 x 1.5 but yours is m14 x 2.


So I made one all sorted


	New carpet with shot holding it down


This is nice I hope you like it


	The spot light switches are here I have fitted some with lights in so you will know when they are on.


Don't worry here is how it is now.


	Rear seats in


This was a curve ball I went to open the light to do the wiring and there was no screw


	Sorted


This took me all day to sort out the wiring for the lights what is wrong with this picture ?


	Inside looking good.


Engine bay looking filled up now


With this manofold the clutch cable has to run around it so I have put some good heat shield on it.


	And the answer is I forgot to fit the spoiler. The only thing I am strugling with is the roof lining we don't fit a roof lining with a cage the roof linings are bad enough to fit without a cage so I can have a go at fitting it if you want but I can't guarantee how good it will look. ( sorry )


Hi Tim a quick few before the car goes to the rolling road I am booked in for 0930 in the morning so fingers crossed.


	Check out the boot fit


	The boiler room after starting the engine sat in the car I have found that the engine mounts are to hard and I will have to change them you can feel to much vibration from the engine sorry my fault I will fix it.


Just one of the few jobs still to do the spoiler has decided it does not fit a mk2 anymore.


	After some major surgery on the boot hinges and brackets we have made the boot fit quite well so it is back on the catch hope that's ok

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