My restoration/upgrade thread...

[NathR]

I've been planning on doing this for about three years but have only now got to a stage where I've got the time to crack on with it!

I thought I'd keep this thread updated with pics to show my progress!

So first stage, cars up in the air, rear bumper/wheels/arch liners off...



Everything looking a bit grotty...





Next the rear beam is dropped...







Fuel tank, handbrake cables, fuel filler all off...





I've started dismantling the beam, some of which using an angle grinder, lots of bolts siezed into bushes.

Thats as far as I've got this week but I'll be spending my spare time stripping all suspension components ready for powder coating and cleaning/painting the underneath.

[dazrsturbo]

nice to see another restro thread on here!

[Daz-cos]

awesome. looking forward to another resto thread. especially as the forums been so quiet lately.

[cozmeister]

Keep us posted Nath

[NathR]

Bit of a progress report from the last week...

Just an example of some of the fun I've been having dealing with lots of seized bolts... 









At last all items stripped and ready for a trip to the powder coaters on Monday...



Old bushes...



New sleeves in arms...





Not sure which route of cleaning up and coating will be best for some of the items (fuel pipes, hub assemblies etc) but I'll take them along and have a chat with the experts!



Whilst they're being sorted I'll be turning my attention to cleaning up and painting the underneath, which I'm not looking forward to!

[matt]

Are you spray or brush painting the under side, and are you going full on buffty body colour? I will guarentee you though that once you've finished you will feel the underside of the engine lets it down and have to bufty that as well. Its a slippery slope.
Here, have some inspiration.......    And bear in mind this was done on a gravel driveway in the middle of winter you lucky lucky BAST*RD.....

[NathR]

The ole RS2000 is looking good there mate! 

To be honest thats my dilemna at the moment, I've gone to the effort of stripping it all down so want to do it properly, also its always kept immaculate so body colour makes sense.  On the other hand I want to actually use the car when its done so keeping it clean would be a ball ache.  I definately want to spray it by some means but the first bit (rust treatment/prime protection/stone chip) will be done with aerosols as its alot easier and will make the least mess in the workshop!  I'm tempted to leave it finished in black stonechip, as full body colour would mean getting the spray gear out and I'm no spray painter, although a demon with rattle cans!    The other option is to get APEC to mix up body colour in aerosols but this would end up being very costly.   

[NathR]

Bit of a progress report.  I've spent lots of hours underneath with the Jizer and APC cleaning the underside this week.  Followed by a spot of indoor pressure washing today!...



Its 90% clean now, the rest will be done bit by bit prior to painting...







There's quite a few rough bits in need of attention which is a bit disappointing considering the cars done 35k miles, is kept immaculate and hasn't really seen rain in the last 3-4 years.  Nothing that can't be sorted however.







I'm a bit undecided what do under there to be honest, leave it stonechip black mainly as its easier to keep clean (I want to use the car when finished) or go fully body colour.  The latter would be trickier as although I have the paint gear to do it, I'm no sprayer and it would make a mess of the workshop.  Also, I would then want the engine out to do the whole job properly.

Anyhow, also been cleaning a few bits up.

Petrol tank...





Heat sheilds...





This product had me properly impressed all morning today, really good stuff...



Half and half pics...





The rear most one is being replaced as sadly the corrosion under the clips has gone too far

Calipers...



They've cleaned up well but I'm tempted to get them blasted and repainted/coated a matt black to match the AP 6 Pots up front.

Some automotive porn to keep enthusiasm up!!...



Thats the setup ready to go on, KW V3s, H&R ARBS and bushes, Powerflex bushes all round, Vibra-Technics rear beam mounts, Eibach adjustable rear arms (not 100% sure I'm going to use these yet), new Goodrich lines as my current ones are a little rough.











The next stage is to get the underneaths rust treated and then everything painted, have to say I'll be very happy when this bits done!  Stuff should be back from the powder coaters within the week and I've ordered all new bolts etc from Ford.

[matt]

Awesome, nice to see it getting some attention after all this time.

As for the underside, i used a wire brush attachment on the grinder to attack the rust and rough the surface up, 'Jenolite' on the rust to kill it, then zinc 182 primer as a base.
For the top coat i got Express Radiators to mix up some cellulose brush on paint in the closest colour match the could, they use RAL colurs so not metalic but a damn good match all the same i think you'll agree.


Personally i think that as the underside of the car is a rough lumpy finish anyway it doesnt matter if its brushed or sprayed on. And dont worry about keeping it clean, as when mine was blue it was easier to keep on top of than originally. The new paint was shiney so didn't hold on to the dirt in the first place so just a quick blast with the pressure washer and some suds and it was done.

RAL 5010 Gentian blue looks a good match 

[RST-Steve]

Nicely done Nath, it's all coming together rather well 

Matt, these pics are just a gentle reminder of just how immaculate the RS2000 was........ seems ages ago now doesn't it when you had that 

btw, all this underside painting etc, have to take my hat off to you.......... thats a LOT of work (although the results speak for themselves) and tbh, not for me......... i'll just polish and keep immaculate the bits i can see pmsl!! 

[NathR]

Thought I'd post a little update. Not too much to show despite lots of hours of work! 

All parts are back from the coaters. The finish is top notch, they have first been coated with a zinc primer to help stop future corrosion.  Also the fuel pipe and hubs have been blasted then wet painted as opposed to powder coated due to not being able to take too much heat with bearings/plastic bits still inside.  The finish on the fuel pipe in the flesh is proper drool worthy!!











The rest of my time has been spent on cleaning up the underside, etch priming as I go.  I'm 80% there now, some bits were pretty rough tbh and have taken quite a bit of cleaning up.





















I've masked off a line just behind the front subframe which the other side of this will be done once the rear is assembled and then the front is stripped.  I've just got the drivers side floor pan/sill area to do now then I'll get my sprayer man in to do the stone chip/base coat/lacquer.    All things well I hope to be at that stage by the end of next Saturday.  Hopefully progress will move on quickly then as it shouldn't take long to put back together, using plenty of copper slip and waxoil here and there along the way to prevent this happening again!

[NathR]

Its been at bit of a busy week at work but I've managed to get a bit done.

Firstly spent a bit of time cleaning up the hubs/stub axels as the coaters hadn't masked off a few areas off which I think need to be bare metal, looks neater now cleaned back rather than a mask line anyhow.



Also, whilst cleaning up the sills I found some funny symbols!



All underneath now cleaned up, primed and masked up...





Stone chipped...





Masked up before top coat...



My view from my office whilst the painting was going on, I didn't believe the bloke when he said it would get a bit foggy, pic doesn't really show how bad it was though...



Base coat/lacquer done...









A little bit of refurbing on the brake line ends...



A few bits from Ford...



Brake lines/new handbrake cable/fuel filter fitted...



Tank back up...



Powerflex exhaust mounts, PD gaskets, s/s bolts/clamp...



Heat shields back up...





My 8 year old Mongoose lets the side down a bit, looking a bit weathered!



Fitted...





Beam fitted, this picture is worth noting for the swearing/time taken to get the exhaust into this bush!





Masked/painted original black bits in wheel arches...





Fuel filler fitter...











Area behind bumper cleaned up and freshly coated rear crossmember fitted...









Lastly bumper fitted...



All assembly was done yesterday so a pretty constructive day, especially given the hangover I had!  All bolt heads etc had are being given a little wiping of waxoil as I go.

Next step is to get all the bushes in arms etc and put the rest of the suspension together, then start on the front end.

[dazrsturbo]

Stunning mate great work! 

[massivewangers]

Looks fantastic Nath, really top work!

[RST-Steve]

Looks great Nath, going to be better than when it was new with all this attention to detail

[NathR]

Cheers guys! 

[bil n kel]

Top work fella, looks well nice. I was thinking of selling the saff and getting a mk1 frs. What they like on fuel? Are there any common problems to look for when buying one?
Billy

[NathR]

Cheers Billy. 

I don't tend to take too much notice of the fuel side of things, also I've hardly driven it for 3 years so have forgot!    I'm sure on a good run I can get nearly 300 miles to a tank, I do however remember only getting 160 miles to my very first tank when I got it, it was standard back then too.

As for problems, other than checking all the usual stuff for general condition they don't, touch wood, seem to have any.   

[NathR]

Update time!

All suspension components ready with bushes in to go back together...





Painted hub nut caps



Calipers fresh from being sent off to biggred for a full reburb/reseal/polymer coating...







Assembled...



All arms/hubs assembled...



Two piece rears...



Rear end complete!!!





Now to the front end







Lots of bits stripped (bumper, lights, grill, cross member, radiator assembly, intercooler and pipework, turbo, manifold, downpipe, thermostat housing, coil, tanks, battery etc etc!









I was chuffed to bits the rear is all back together and looking properly bling, for comparison...





But now I've started stripping the front it feels like I'm back to square one!!

[NathR]

Right guys, its been a while and I've been a bit busy but time for a bit of an update...

All front suspension/rack/driveshafts off...







All stripped down along with a few brackets etc ready for the coaters...





Had to replace the n/s hub due to me keeping my foot in at a trackday a few years back when the hub nut worked itself rediculously loose. :wall: (I'll describe the mess it made of my AP caliper in another update! )

You can see the damage done along with the difference between a 'normally worn' one and a new one...









All the above are being coated as we speak so things should come along soon.

Back to the bodywork, wings/crossmember/slam panel have been removed...





Then masked up for tidying/painting, the masking alone took me a day, properly fiddly...





Everything prepped and primed...











Car stoned chipped...





And painted...







The crossmember has been blasted and will be painted along with the inside of the wings next week.  I've decided to leave the slam panel as its clean enough and then will leave the engine bay with the original finish throughout.

Fingers crossed over the next few weeks she should start coming together quickly then the exciting parts like upgrades can be fitted.   Frustratingly though the next two months are really busy for me with things like my 30th, Nurburgring/Rock Am Ring trip/other music gig trips away so progress may slow down even more. :wall:  I've booked a track day at Spa for the start of October now along with another Ring trip so the pressures on to get it together, outside paintwork tidied, MOT'd, geometry set, good few road miles and shake-down track day to make sure everything is 100%! :eek:

[massivewangers]

Nice to see it still progressing. Going to be one of the best around at this rate. Out of interest, where did you get the carbon upper cambelt cover? Any details?

[NathR]

Cheers mate. 

Carbon cover was from Carbontec who sadly don't trade anymore, which is annoying as I was wanted to buy a plug cover from them!

[massivewangers]

That's a shame, would like one of those for my build!

[RST-Steve]

Wont be long until it's done now, it's coming together rather well

[NathR]

I'm long due a bit of an update although I've been pretty busy of late so progress has slowed down a bit.

Anyhow, a few suspension bits...





New AP organic clutch and new slave cylinder...



Gearbox treated to a bit of a clean...



Clutch in...





New cambelt and tensioners...



SCC GT28 Turbo (compressor housing turned round), PD GT28 Manifold, Miltek Divorced Downpipe, all ceramic coated...













Vs standard...







The work of art that is Wombles thermostat housing... :cool:





Crossmember and brackets blasted and painted...



All PAS pipes have been sanded down and painted, pic for comparison...



Pro Alloy Radiator (black coated)...







Fans/rad assembled...



Pic of the rack and driveshaft for comparison later...



Front end stuff back from coaters...









A few bits I've painted...



All subframe and front suspension assembled...





Front end is coming together now, rad fitted along with manifold/turbo/downpipe...



Few close ups of the turbo, looks proper tasty in the flesh!!...







Front wings painted inside...



...and fitted...





As of the end of today that is how the car stands, suspension all ready to bolt up.  Driveshafts have been cleaned up and painted (last job today!) so it shouldn't take long to put back together now.

Other than that I'm waiting on James @ JEK for one of his turbo oil returns. Pro Alloy have my intercooler/pipes/battery tray/header & PAS tanks for coating black along with modifying the lower pipe for the reversed turbo housing and also supplying all black silicone houses instead of my old blue ones.  I've then got to come up with some form of PAS cooler as the original setup always boils over on track.  I think I'm finally getting somewhere now!