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  • #16
    Originally posted by Tango View Post

    small bit more for the welding/fabricating fetishists out there.

    *Disclaimer* I am self taught on all this stuff, about 15 months on and off as a fabricator/general operator in company in my late teens/early 20s is my experience, plus what I've learn at this over the last two years!!

    this started as a 1 inch square hole at the front of the pocket before i started poking, what i thought was one evenings work ended up taking most of my free time for a week!!
    pocket 1 by John Teahan

    chopped it off and saw the scabs on the outer side, and realised the only way to do it properly was to get cutting
    pocket 2 by John Teahan

    so i hacked off the outer skin of the pocket...
    pocket 3 by John Teahan

    fabricated a new inner skin for the pocket
    pocket 4 by John Teahan

    welded the new inner skin in place
    pocket 5 by John Teahan

    made a piece to replace the scabby bit of the outer skin and grafted them together, i wanted to save the back corner as it is all compound curves and it was in decent condition
    Pocket 6 by John Teahan

    and here it is all welded back in place:
    pocket 7 by John Teahan

    Pocket 8 by John Teahan


    another little repair I hadn't planned, when removing the front wing it was apparent the front corner welds holding it on were not OE, on further inspection it was rusting from the inside and the full extent of the issue was obvious once I ground the paint off
    wing 1 by John Teahan

    knocked up a replacement corner piece, I foolishly followed the lines that the wing had, forgetting that i had just ground off some filler on that exact corner, i didn't cop it for about 6 months (Last saturday) when i lined up the bonnet and that corner didn't follow the bonnet correctly. oops. its corrected now...
    wing 2 by John Teahan

    wing 3 by John Teahan

    More of this please... This is my :D:D:D:D ha. Might give me motivation to get back at the e30 build

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    • #17
      Originally posted by Smythy411 View Post

      More of this please... This is my ha. Might give me motivation to get back at the e30 build
      tis funny, its mainly youtube stuff like Dan Chambers, Terry Slucock and AaronUnknown that motivate me to have a craic at stuff, and as strange as this might sound i've been surprising myself with what i've done so far which kinda spurred me on to finish it.
      Never thought I might motivate someone else though!!

      i'll look through some other bits i've done on it and see what else is worth sharing, some like the bottom of the A pillar is UGLY but functional, its behind the wing so never seen and I was more concerned with chopping out the rot and returning the strength as it was. i've gotten better as i've gone on, I think I would be neater now, its all learning

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      • #18
        Originally posted by DaveD_XB View Post
        I love these old fast Fords, when I first got my license & was driving around in a twin Carb Civic I was always getting absolutely chopped by these... would have loved to own one, but because I'm a bit odd I always wanted the big whale tail version... I just loved how they looked..

        Looking forward to seeing your progress
        These RS turbos were decent for the time, there is a fifth gear video of Tiff Needell comparing a mk2 Astra GTE to a mk4 escort RS turbo, the escort is faster around their track.
        Straight line race to top speed and the Astra was the fastest hatch at the time, no question, but the mid range torque from a 1600 turbo and the light nimble chassis helped the Ford.

        Its amazing how cars improved from the 70s to the late 90s, daily driving a 70s car in the 2000s would have been a chore, this thing was completely usable all year around for me right up to 2014. things people take so for granted now, but this was weather tight, good heater, good wipers, plenty of power to keep with traffic, enough grip and traction to keep out of trouble. On modern tyres you would need to be going fairly nuts to get the thing out of shape, ABS is the only safety thing you might do with, I never locked a wheel on it though.

        As someone said on here recently, the improvement in cars over the last 20 years has been mainly NVH (and safety) related, nothing that makes them better to drive or more reliable.

        Comment


        • #19
          couple of little odd jobs that needed doing in advance or reassembly, one was the clocks, the numbers on the speedo were peeling off and making it look rubbish, so I got new clock faces from lockwood (remember when putting different colour dials in was a must have mod to make max power)
          clock 1 by John Teahan

          i resisted the temptation to go for that ultimate 90s mod and went or the OE looking black dials.
          clock 2 by John Teahan


          another task that needed doing was some of the studs for the front arch trims had snapped on disassembly, one guy online swore by araldite to bond in new studs, but after trying it to fix some other items and being unimpressed i went with fibreglass. I did a test and bonded a nut to a piece of plastic with fibreglass so i was convinced it would work
          stud 1 by John Teahan

          I ground out a pocket for the head of an M4 stainless steel nut
          stud 2 by John Teahan

          and bonded it in place. i ground down the excess after, I didn't take a pic of that though. in total I had to do half the studs on the arches, the other 4 I ran an M4 die over to make sure the threads were still ok.
          stud 3 by John Teahan

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          • #20
            these just disappeared over the last decade or two, just like XR2i's and the like. Great to see an 80/90's hot hatch getting some love, rare on this side of the water now!
            looking back now, I think that maybe, every now and again, I should have braked a little earlier

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            • #21
              The pictures dont do the work justice. savage progress over the last 2 years. i cant wait for this car to be back on the road.
              BAD SPELLERS OF THE WORLD UNTIE

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              • #22
                Nice work - I’m hoping to get mine out on the road after a full restoration - I did reshell mine. Let me know if looking for any parts I’ve all kinds of odds and sods.

                Comment


                • #23
                  Originally posted by chewypops View Post
                  The pictures dont do the work justice. savage progress over the last 2 years. i cant wait for this car to be back on the road.
                  thank you Mr Chewypops, you’ve seen first hand the misery!

                  no doubt you’ll be the first to get a spin in it

                  Comment


                  • #24
                    Originally posted by simonmcf View Post
                    Nice work - I’m hoping to get mine out on the road after a full restoration - I did reshell mine. Let me know if looking for any parts I’ve all kinds of odds and sods.
                    I initially thought reshelling was my only option, but this shell was solid in the important areas.
                    outer sills and footwells are gone/ going in most of these so better the devil I knew.

                    I might be reaching out to you on some parts, I think 2 of my roof grab handles were damaged

                    Comment


                    • #25
                      Oh boy, serious welding and fab skills Tango. The bit where you're like "and here;s the inner pocket I made" and I see multiple features on it that I wouldn't have a notion where to start with And I do love a long termer, looking forward to reading more.

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                      • #26
                        Originally posted by dimitri View Post
                        Oh boy, serious welding and fab skills Tango. The bit where you're like "and here;s the inner pocket I made" and I see multiple features on it that I wouldn't have a notion where to start with And I do love a long termer, looking forward to reading more.
                        Thank you, my welding needs work, I’ve been lucky enough to learn from some very clever and talented fabricators, if I get half as good as them I’ll be happy.
                        My fabricating tools comprise of a Clarke sheet metal folder, a hammer and various pliers and whatever bits of pipe and round I have lying around

                        Comment


                        • #27
                          Originally posted by Tango View Post

                          I initially thought reshelling was my only option, but this shell was solid in the important areas.
                          outer sills and footwells are gone/ going in most of these so better the devil I knew.

                          I might be reaching out to you on some parts, I think 2 of my roof grab handles were damaged
                          Think I’ve a pair there. You can have em if I can dig them out

                          Comment

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