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cosworth swb mk4 project....

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cosworth swb mk4 project....

Postby Gavin » Sun May 04, 2008 3:44 pm

mk4 petrol efi with 66,000 miles, well looked after and looks tidy but still quite a bit needs doing, think i caught this one at the right time.....

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bullbar has gone, work has started :D

only cleaned the rust out of the right hand side so far.....the other side is worse.... :!:

lower rear quarter.....

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new panel trial fitted....

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edgesetter helps get the fit right...

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take note int :lol:

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hole on the inside ove the spring hanger outrigger....

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lots of small holes....

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and an odd one, rusting from under the paint but no visible hole in the paint inside or outside :!:

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front arch, bit of surface rust and a small hole caused by the mudtraps....i mean mud flaps :evil:

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and the step......sad face :lol:

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while i was at it i fitted these..... 8)

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Last edited by Gavin on Sat Jul 03, 2010 4:54 pm, edited 1 time in total.
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1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: started work on the red van...

Postby Luke » Sun May 04, 2008 5:32 pm

nice one mate 8) like you say caught it at the right time 8) repair those bits and plenty of waxoil and be good for years :D
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Re: started work on the red van...

Postby Ford Sprung Van Tastik!! » Sun May 04, 2008 5:50 pm

Nice looking van :)
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Re: started work on the red van...

Postby Gavin » Sun May 04, 2008 6:26 pm

Luke wrote:nice one mate 8) like you say caught it at the right time 8) repair those bits and plenty of waxoil and be good for years :D



yup, my old mk2 escort was a rot box back in '89 when it was just 13 years old. i welded it all up and put about 5 gallons :!: of waxoil in it and all over the underside. it used to dribble yellow puss in the summer when it sat out in the sun all day :lol: but i just sold it (18 years after i rebuilt it) and it was still pretty much as sound as the day i put it back on the road... 8)

its no wonder these trannys rust though, inside all the box sections all it seems to have had is a single dip in the paint tank.....and once its got rust under the paint, the paint is just peeling off like rice paper :!:

even my old escort seemed to be better protected from new!
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: started work on the red van...

Postby custom » Sun May 04, 2008 6:31 pm

that looks like a wicked van mate and in good nice will look mint when u have finished it
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Re: started work on the red van...

Postby intransit89 » Mon May 05, 2008 11:08 pm

i i see the rear bits i got to do both of mine to and rear archers and in front of the archers to the sliding door both sides :lol:

and i got to weld my drivers side step to same place in the corner iam gona weld a new pice from the plastic trim to the bit where it joins the holes for the plastic step to clip in 8)

i bet you wish you hadnt sold your archers for the front when you get looking :lol:

got my sills and front archers sorted tho :!: :wink:

nice work :D
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Re: started work on the red van...

Postby Gavin » Mon May 05, 2008 11:48 pm

intransit89 wrote:[i bet you wish you hadnt sold your archers for the front when you get looking :lol:






not at all mate, all you see is all there is.

beat out the rust between the seams, rust eater, kurust it, zinc etch primer filler and paint and plenty of waxoil and they'll not need to be changed.

same with the cill and that step.

I'm not a believer in cutting great chunks of metal out of cars. if you remove whats rotten and properly treat and protect whats left it will last for years.
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: started work on the red van...

Postby Gavin » Fri May 16, 2008 11:57 am

lower corner ready for welding. all primed inside and out with weld thru zinc etching primer, inside the rust has been cured painted and patched, and then painted over again. going to seam weld the top edge and the back edge, the bottom and the front have been drilled and that will all be plug welded and ground back.

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inside i've cut and shaped this panel, still need to drill some holes to pick up the spring hanger outrigger and will plug weld these. The edges will be seam welded, then i'll use some brushable seam sealer and paint it all red like its supposed to be :D

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2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: started work on the red van...

Postby MR BigBeefy LDV Guru » Fri May 16, 2008 12:00 pm

some high quality work going on here
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Re: started work on the red van...

Postby Gavin » Fri May 16, 2008 7:42 pm

thank you! :D

not so happy with the welding, bought a new reel of fluxed wire and it would go fine then a bit splattery on the same strip of clean metal. ive found this before with SIP reels, sometimes it seems the flux is intermittent :?

still, plate inside is done, im tempted to grind down the plug welds to neaten it up but its going to be boarded over anyway, so maybbe i'll just paint and seam seal it...

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2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: started work on the red van...

Postby Luke » Fri May 16, 2008 7:50 pm

quality work 8) always nice to see :D
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Re: started work on the red van...

Postby Paul 1 » Fri May 16, 2008 7:52 pm

Very tidy job, Intransit take note Lol
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Re: started work on the red van...

Postby Gavin » Sat May 17, 2008 1:01 pm

welded the lower rear panel on this morning, ground it all back.

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the rear edge ive just stitched and will fill with sealant or filler, originally it was spot welded on the lip inside, but as a repair panel theres no way to do this!

i made a mistake, drilled one of the plug weld holes at the bottom over a drain hole, so to fill it o flattened a bit of 15mm copper tube and shoved it behind the drilled hole and filled it with weld. the copper wont stick to the panel or the weld, so when i was done i just took it out and the panel hole was nicely filled.

cant do anymore right now, its pissing down on my bare welds. arsefek :evil:
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: started work on the red van...

Postby MR BigBeefy LDV Guru » Sat May 17, 2008 1:15 pm

thats just how it should be done i bet you wont need more than a golfball size of filler on that

nice tip about the copper there m8 i would of never thought of that :!: :!: :!:
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Re: started work on the red van...

Postby Gavin » Mon May 19, 2008 10:17 pm

i could probably get away with a few coats of filler primer on the seam, but i will stick some p38 on it anyway.

i got the front step welded up over the weekend, shaped and edgeset pieces as before.

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im not liking this new reel of wire at all, just cant get any consistency with it :( ive always (like 18 years since i started welding!) used flux cored stuff but im thinking about getting a bottle and having a go with mild steel wire instead....

sprayed both the step and the rear corner up in primer for now, will get round to filling and finishing later, right now im on a deadline for the welding, 3 weeks to go. still got a couple of patches to do on the cill on this side, then theres a couple of patches in the rear crossmember and on the other side ive got the whole rear arch panel and the cill under the door..... :(
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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