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GAS FAB Mk1 Escort

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  • garvice
    replied
    So, started in on the next car.

    https://performanceforums.com/forums...s-fab-xm-coupe

    Leave a comment:


  • Cliffordcliffs
    replied
    Incredible work to bring back the escort Brad! Many thanks for taking the time to detail the repair process.

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  • Alan M
    replied
    I expect progress to be slow, although it should be painted in the next couple of months, and then the work really begins.

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  • Ben Wilson
    replied
    Originally posted by Alan M View Post
    We picked up the Escort last Friday. Very happy with the result. Garvice gives an update with pictures and script on the car each week, with a weekly invoice. It is good system with everyone knowing where they stand, and Garvice not being left out of pocket for months of work when an owner either gets in trouble, or finds something else to spend money on. The car will owe $25-28K when finished, even with us doing the mechanicals ourselves, and the Escort will be getting painted the original yellow, and made to look like a 1600 Mexico. We are currently stripping the paint and etch priming, for a trip to a panel shop. Hopefully Garvice will be still doing this work in a couple of years when I get around to restoring a 1971 BMW2002 that I have had sitting in a shed for ten years.. Like most '70s machines it also has a fair share of rust, but maybe only a third of the Escort, once you replace the boot lid and bonnet, but you don't know what is beyond the surface. Thank you again Brad for your efforts on the Escort. Your work on the car has been as if it was your own.
    Please keep us updated on the rest of the progress

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  • Alan M
    replied
    We picked up the Escort last Friday. Very happy with the result. Garvice gives an update with pictures and script on the car each week, with a weekly invoice. It is good system with everyone knowing where they stand, and Garvice not being left out of pocket for months of work when an owner either gets in trouble, or finds something else to spend money on. The car will owe $25-28K when finished, even with us doing the mechanicals ourselves, and the Escort will be getting painted the original yellow, and made to look like a 1600 Mexico. We are currently stripping the paint and etch priming, for a trip to a panel shop. Hopefully Garvice will be still doing this work in a couple of years when I get around to restoring a 1971 BMW2002 that I have had sitting in a shed for ten years.. Like most '70s machines it also has a fair share of rust, but maybe only a third of the Escort, once you replace the boot lid and bonnet, but you don't know what is beyond the surface. Thank you again Brad for your efforts on the Escort. Your work on the car has been as if it was your own.

    Leave a comment:


  • Komdotkom
    replied
    Fantastic work mate, best thread on PF at the moment!

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  • garvice
    replied
    Thanks mate.

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  • BLO 767
    replied
    Fantastic job on the panel gaps. Really great stuff! Such pain in the ass work when they need that much "massaging".

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  • garvice
    replied
    Unfortunately GAS FAB is only a part time gig for me, every Friday and sometimes some weekend work. I also have to fit the general fabrication type work in that day too, though the last year has definitely been more car work than anything else. The car on the hoist is my personal 1600 that might one day get done but I'm not holding my breath.

    Leave a comment:


  • 9triton
    replied
    nice update

    cant wait to see whats next.

    do you work on few at once? i see another on the hoist

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  • garvice
    replied
    Next was the passenger side quarter panel. I had left this one till last as it was actually worse then the driver's side.


    Gaps were better along the bonnet but still uneven.

    GAS_FAB_Mk1_Escort_270 by GAS FAB, on Flickr


    At the windscreen they were pretty good.

    GAS_FAB_Mk1_Escort_271 by GAS FAB, on Flickr


    But the door gaps were woefull! That's over 13mm at the bottom and sticking out from the door by about 5mm in the middle.

    GAS_FAB_Mk1_Escort_272 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_273 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_274 by GAS FAB, on Flickr


    And the front valence didn't fit real well either.

    GAS_FAB_Mk1_Escort_275 by GAS FAB, on Flickr


    The bonnet also sat a fair way lower

    GAS_FAB_Mk1_Escort_276 by GAS FAB, on Flickr


    With the bonnet gap evened up, the back top corner of the guard now sat to far in towards the car.

    GAS_FAB_Mk1_Escort_277 by GAS FAB, on Flickr


    Closing the gap to the door was going to take too many passes with the mig, so instead I lengthened the guard by welding 2.4mm diameter tig rods along the edge. Along the bottom half I had 3 tig rods welded along the edge, that's over 7mm of material added!

    GAS_FAB_Mk1_Escort_278 by GAS FAB, on Flickr


    I tried to pull the top of the guard out and get the middle of the guard in, but I just couldn't get the guard to cooperate. The guard was just rounded too much. So, to fix it, I had to cut the inner support and take some bend out of it. This is a photo of the test extension before welding the gap closed and dressing it down. I didn't get a final photo. I also had to undo the spot welds on the skin at the top corner of the door to allow it to come up and out. These were reset at the new position.

    GAS_FAB_Mk1_Escort_279 by GAS FAB, on Flickr


    The middle of the guard sat flush with the door now.

    GAS_FAB_Mk1_Escort_280 by GAS FAB, on Flickr


    And the top fit much better.

    GAS_FAB_Mk1_Escort_281 by GAS FAB, on Flickr


    So the guard gap was ground back even.

    GAS_FAB_Mk1_Escort_282 by GAS FAB, on Flickr


    And I thought I'd take a photo of how much the door moves forward as you open it, as I had to have the guard to door gaps at about 5mm to clear.

    GAS_FAB_Mk1_Escort_283 by GAS FAB, on Flickr


    Finally, it was time for some bling with the NOS front grille. Most of the mounts I could make work but the top outside holes completely missed the holes in the radiator support.

    GAS_FAB_Mk1_Escort_284 by GAS FAB, on Flickr


    So new mounts were made.

    GAS_FAB_Mk1_Escort_285 by GAS FAB, on Flickr


    And the old girl looked so much better then when it started.

    GAS_FAB_Mk1_Escort_286 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_287 by GAS FAB, on Flickr


    Don't have photos up, but there are 4 rivnuts along the top flange of the car to bolt the guard on, one at the sill, two on the valence and then two captive nuts behind the grille. I haven't used rivnuts much, so I'm pretty sceptical of them and prefer to weld in captive nuts. So I did what I thought felt natural, after crimping them in place I tack welded each one in three places to make sure they never move.


    So, owner is coming over on friday to do a once over the car and hopefully call it done.
    Last edited by garvice; 26-08-20, 09:19 PM.

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  • garvice
    replied
    The front quarter panels were reproduction panels supplied with the car. I had been putting these off as they just didn't fit. First tackled was the driver's quarter.

    It touched at the front of the bonnet and had about an 8mm gap at the back.

    GAS_FAB_Mk1_Escort_254 by GAS FAB, on Flickr


    At the windscreen it flared out away from the car.

    GAS_FAB_Mk1_Escort_255 by GAS FAB, on Flickr


    The guard stuck out from the door by a good 7mm

    GAS_FAB_Mk1_Escort_256 by GAS FAB, on Flickr


    And the gap between the guard and the door was about 8mm in the bottom 2/3rds and about 5mm at the top.

    GAS_FAB_Mk1_Escort_257 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_258 by GAS FAB, on Flickr


    So, the guard came off and on about 20times during the works.
    I had to massage the inner support at the rear to bring the rear in, and massage the front of the guard around the valence to bring it out. This got the bonnet gap relatively even.

    GAS_FAB_Mk1_Escort_259 by GAS FAB, on Flickr


    But this in turn destroyed the gap to the windscreen, we were now touching.

    GAS_FAB_Mk1_Escort_260 by GAS FAB, on Flickr


    So I cut the back/top of the guard and rewelded it with an even gap.

    GAS_FAB_Mk1_Escort_261 by GAS FAB, on Flickr


    Then I had to turn my attention to lengthening the rear of the guard to close the gap to the door. This side I just mig welded on a few passes of beads.

    GAS_FAB_Mk1_Escort_262 by GAS FAB, on Flickr


    These guards are traditionally spot welded on, but the owner wanted them to be converted to bolt on. So I made some mounts for the guard.

    GAS_FAB_Mk1_Escort_263 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_264 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_265 by GAS FAB, on Flickr


    And went for yet another test fit.

    GAS_FAB_Mk1_Escort_266 by GAS FAB, on Flickr


    This time with the mig bead extended guard ground down to an even gap. I had to leave the gap about 5mm as the door moves forward quite a way as it swings in.

    GAS_FAB_Mk1_Escort_267 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_268 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_269 by GAS FAB, on Flickr
    Last edited by garvice; 26-08-20, 09:14 PM.

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  • garvice
    replied
    I love seeing updates from this thread. Wish I had skill or talent.
    Only one way to get it, give it a crack.


    So, in the few weeks the forum has been down, I have manage to finish the escort (pending customer's inspection). So get the popcorn out, this is going to be a long one.

    The engine bay had a few spots that had been previously repaired.

    GAS_FAB_Mk1_Escort_248 by GAS FAB, on Flickr


    The first repair was a lap welded panel that was going to be filled over. I cut it out and butt welded a new piece in.

    GAS_FAB_Mk1_Escort_249 by GAS FAB, on Flickr


    Next was some holes that had been filled with the mig, so they also got cut out and a patch but welded in.

    GAS_FAB_Mk1_Escort_250 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_251 by GAS FAB, on Flickr


    Finally there was a small patch that had been stuck on the back then filled with mig from the front. Same approach to repair it.

    GAS_FAB_Mk1_Escort_252 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_253 by GAS FAB, on Flickr



    Last edited by garvice; 26-08-20, 09:11 PM.

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  • Lobster
    replied
    I love seeing updates from this thread. Wish I had skill or talent.

    Leave a comment:


  • garvice
    replied

    So, somehow 10 years has gone by in the blink of an eye and I now have a 10year old son! Not sure where that time went.

    Anyway, since it was his birthday, I only got half a day on the escort this week, so I decided to tackle the doors.

    Driver's side door had a small rust bubble at the front bottom corner.

    GAS_FAB_Mk1_Escort_226 by GAS FAB, on Flickr


    Unfortunately, if you have bubbles in your paint, this is what is normally behind the outer skin.

    GAS_FAB_Mk1_Escort_227 by GAS FAB, on Flickr


    And cleaned up, a pitted/rusted through door frame.

    GAS_FAB_Mk1_Escort_228 by GAS FAB, on Flickr


    So a patch gets made up for the frame (always go larger then you think you'll need.

    GAS_FAB_Mk1_Escort_229 by GAS FAB, on Flickr


    Trim back to fresh metal

    GAS_FAB_Mk1_Escort_230 by GAS FAB, on Flickr


    And weld it in

    GAS_FAB_Mk1_Escort_231 by GAS FAB, on Flickr


    Followed by your outer panel repair patch.

    GAS_FAB_Mk1_Escort_232 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_233 by GAS FAB, on Flickr


    I also sanded back the rest of the bottom of the door, treated the surface rust and primed. This is the door fitted.

    GAS_FAB_Mk1_Escort_234 by GAS FAB, on Flickr


    Passenger door was a different story. I think it had been bent back on itself (backed into something with the door open). The front of the door was bent out, with a big crease, the hinges were bent in the door frame, the extension catch had ripped into the door frame, there was damage in the middle of the panel covered with bog and the bottom edge of the door frame was rusted but the skin was solid. To get this perfect, it probably needs a new skin and a door frame rebuild. However that's a fair bit of work/expense. So I decided to treat the rust in the bottom of the door and spend minimal time panel beating the current skin. This will still have a fair bit of life left in it now and can always be replaced in the future if required.


    Crease at the front of the door.

    GAS_FAB_Mk1_Escort_235 by GAS FAB, on Flickr


    Planished most of the crease out, but was hard work getting behind it.

    GAS_FAB_Mk1_Escort_236 by GAS FAB, on Flickr


    Can just make it out with primer on.

    GAS_FAB_Mk1_Escort_237 by GAS FAB, on Flickr

    GAS_FAB_Mk1_Escort_238 by GAS FAB, on Flickr


    Middle of the door had bog above and below the door lines.

    GAS_FAB_Mk1_Escort_239 by GAS FAB, on Flickr


    Planished some of the creases out and used a small prybar to try and get the shape back into the door line.

    GAS_FAB_Mk1_Escort_240 by GAS FAB, on Flickr


    With some primer on you can make out where there is still some creases in the door. Can maybe spend a little more time on that lower crease but how it is now will be a lot less bog then what was on it to start with.

    GAS_FAB_Mk1_Escort_241 by GAS FAB, on Flickr


    Rust in the bottom of the door frame.

    GAS_FAB_Mk1_Escort_242 by GAS FAB, on Flickr


    Cleaned up, treated and primed. It will eventually need to be addressed but this should last quite a while if treated right and kept clean/dry.

    GAS_FAB_Mk1_Escort_243 by GAS FAB, on Flickr


    Hinge had been pushed in and door frame twisted.

    GAS_FAB_Mk1_Escort_244 by GAS FAB, on Flickr


    Looking at the photos now it's hard to see much difference, but the door hinges now align a bit better.

    GAS_FAB_Mk1_Escort_245 by GAS FAB, on Flickr


    The skin had come away from the intrusion bar and was moving around a bit, so I reglued/sealed it back on.

    GAS_FAB_Mk1_Escort_246 by GAS FAB, on Flickr


    And the door back on. It was hard to get a photo as I had the escort pushed hard against one side of the shed to give me room on the driver's side.

    GAS_FAB_Mk1_Escort_247 by GAS FAB, on Flickr

    Last edited by garvice; 01-08-20, 03:04 PM.

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