mk1 cortina with 4age install

**64sam** · 01-04-2010, 19:40

i went and got gas this morning and finished off welding the collector back onto the manifold

then i went and did the "rest of the system"

and one of my improving welding

then i did a couple of the small rust repair jobs that needed doing

i know the exhaust is going to be really loud and not the best to drive but i'm good with both those

plan for tomorrow is patching up a few more holes and then maybe look at the throttle linkage

**Jon** · 01-04-2010, 20:00

will email him the picture now ;-)

**64sam** · 02-04-2010, 22:22

having had a bit of advice on my welding i cranked up the mig and took on modding the clutch pedal to keep the standard pedal height with the shorter master cylinder pushrod.

(don't worry i welded both sides before grinding it flat.)
then the plan was to patch some rust that i'd cut out of the drivers side kick panel

but then i noticed some rust on the inner side of the wing... in the middle of the three layers between the front wing and the kick panel and then saw what i thought was some expanding foam inside the sill

a little poking with a screwdriver from the outside and i thought i had a bit of a patch job coming up

then out with the grinder which reviled it to be one of tow golf ball sized pieces of filler held in place with metal that looked more like a spiders web than a sill

now this wasn't meant to be a resto and this is the first time i have done anything more than change a tire on a car before so i have a couple of questions...

1st how do i go about reparing the hole on the panel between the wing and kick panel?

2nd how is best to repair the sill? i don't really want to buy a new one as they are extremely expensive and it is only this front section that looks to need attention. is it worth me plating it over to get it past an mot and then give it some proper attention over the winter because i really want to get this on the road for the summer and enjoy it,

**64sam** · 03-04-2010, 22:26

ok today i had i bit more of a poke around my rotten sill... looked like it was only the inner and outer sills that were rotten and what i thought was a hole in the middle of the three layers was just some of the old sill that had been left there, probably when it was "repaired" with filler.

anyway i cut away most of the rotten inner sill before i ran out of cutting disks, will do the rest when i can get underneath the car properly then i can start the repairs

with that about as far as i could get without more cutting discs or axle stands i welded up the holes made when the battry tray was cut out (not by me)

i also had to play fire marshal because the underseal kept on bursting into flames for sum reason

to be able to get to all the rot cut out of the outer sill the door had to come off this felt like a massive step backwards so to cheer myself up...

detachable steering wheel!!!!!!

this will probably be the last update for a while because i'm back to uni on monday... oh well it will give me a chance to get the repair panel and a few more bits sorted.

**gpcmatric** · 03-04-2010, 23:46

which sill side do you need may have one side?

**gpcmatric** · 03-04-2010, 23:52

got n/r side sill you could probably cut it and use part of it?

**gpcmatric** · 04-04-2010, 16:47

pmed mate

**SpenceSpecial** · 05-04-2010, 20:07

Cars looking good dot the same engine planning on putting it into an escort mk2

**64sam** · 06-11-2011, 18:31

long time with no progress but today this is what i have to work with atm

i got the custom prop-shaft fitted which was a relief as the first one they made was too short and had the wrong flange on it.

i thought that i'd check that the starter motor works before bolting it onto the engine but unsurprisingly the battery was flat so will have to check that tomorrow once it's had a full charge.