Transit Mk5 recon - engine and body

[NapraP]

Hi guys!

My old rusty transit need some care (a lot of care). I spent week of my life for it. Here is some photo from my work. Please be patient with my english and some deficiencies in my work (I am not service man - only hobby mechanic).

Here is few photos of my tranny before recon...











Deep cleaning...



engine like new


holes like new


under the skirt


Prepare for welding...









fitting some iron...













...to be continued...

[NapraP]

Sorry for pics - just repaired...

Here is few photos of my tranny before recon...












Deep cleaning...




engine like new



holes like new


under the skirt


Prepare for welding...












I need keep back of step cos renewal vin code is problem in the Czech Republic (i not need problems with police so it´s easier keep it than make own new vin code)










born of new edge...

it was fu*king work for me (I am only hobby mechanic - not professional)

























Engine recon...

I don´t want to tough camera with my oily hand - so I have only few photos...






engine like new
cylinders look likes new - really nice hatch on it. Pistons rings burn alive but pistons still have grooving like new - without polished places. New main bearing, con rod bearing, piston rings, all gasket, injectors, new diesel transport pump (engine sometimes lost power and start jerking), leak-off mod...I am looking forward to first start and first drive...

Painting...




five bottles of bottom protect was too little...

...to be continued... it was too much work for one week to do all, next weekend I must install new clutch set, put back gearbox, drive shaft with new bearings and prepare it all for painting...

2000 pounds spent and car not done...unfortunately for me I love this transit

[BigMonty]

My Friend you are mad ! Very few people would have took on a job like that. Its great to see a transit reborn !
Where are you ?

[landiman]

WOW, thats some project........ great seeing work being done... Hat off to you chap keep up the good work

[transitandy]

Im very impressed with you work m8 well done you

[NapraP]

Thanks a lot guys!

To BigMonty:

I am from the Czech Republic/in the Czech Republic more known as Czechoslovakia (before split to two countries)...so please be patient for my english - I never use this language in real life so my grammar is very bad...

to all:

Thanks again!!! I feel like stupid that I make this reborn. For this money and job I can buy newest transit but I like this one. It´s hardworker, no electrical systems on car - only old atmospheric diesel from stone age and iron. It´s one of last good car by Ford for me. If you can see big end bearings that you don´t trust that this engine can work. Lot of cracks, holes in it, piston rings totally K.O.. Injectors almost melted down ....and this car still run like slave for his master. One of my friend told to me: "This old transits not ill, they still work, then die".

It will be long run to make all like new. For example: I can´t sleep now cos I don´t painted some part (inner parts of rear wings) before I weld it on car - it is only protected by cavity wax and bottom protect. I wish that not rust for some years but I don´t know.

I wish that my photos and work will help anybody in question "weld up or melt down". It is the reason why I torture my head with english and start this thread...

[lampy54]

Your English is very good and your enthusiasm even better, many people would not even attempt what you have done

[steviebee]

Hi NapraP, great pictures. I will be doing my wings and arches this summer. your pictures have made it very clear as to what I have to do. And as for your English its fine, 2000 times better than my Czech . great work there mate, well done!

Steve.

[NapraP]

I wish I have more pics from engine recon. Is advantage that this engine is very easy to recon. My Haynes does not include torque for con rod nuts. Here is it from Official Ford service: 1st grade 54Nm , 2nd 69Nm.

[KING OF ENGLAND]

Hi, thats a great job you are doing im looking forward
to seeing the end result,well done mate

[NapraP]

To KING OF ENGLAND:

This battle will be very rigid. I have plan - this time /engine+welding+painting of repaired parts + repair all broken parts (new clutch, brake shoes, main brake cylinder etc....) I haven´t got so much time and money now to do all. Next year I want to fit turbo, mount new brake discs ( very NICE! http://www.mtecbrakes.co.uk/index.php?main_page=product_info&cPath=4&products_id=8675 - drilled and grooved of course ). Make all brake tubes new, better audio, protective frame to front etc...

I have on rear wheel hub prepare for ABS (only wreath) so I want fit ABS sensors, ABS modulator on it and make small controller for ABS modulator for traction control (ON/OFF switch on dashboard and "black box" which will compare rev on rear wheel then brake spinning wheel...)

So like you can see a lot of water will flow in river before all will be finished

[peepingTOM]

youve made everyone elses rebuilds on smileys look like a half day job!. AWSOME WORK M8.

[mrepson]

very nice work your doing your repair panels are alot better than the panels, we can get over here,i like the full outer sill with full wheel arch on, and with half a, b pillar,and the door step complete with the inner sill on,i wish we could get panels like this

[dieselhead123]

I like the full outer sill with full wheel arch on, and with half a, B pillar,and the door step complete with the inner sill on, I wish we could get panels like this

Those panels are available mate, just check the Mk5 body panels thread or pm me your requirements.

TIM

[NapraP]

To mrepson:

This parts is very poor Poland aftermarket. I invented a lot of new bad words when I tried to fit this part to car. It isn't visible from pics but it was terrible work. Left side take almost one day of hammering and cutting to fit (door step X sill X door)...

In all case - in the morning I will go to weekend house to continue work...

Plan for this week:

Finish chassis protect, fit new clutch set, mount gearbox, mount prop shaft, clean and mount fuel tank, mount new exhaust, mount new brake shoes + new rear wheel hub oil seal, mount new plastic arch protect, paint floor and sides in "cargo" space and prepare car for paint )