The original phone conversation with the owner was pretty normal for us regarding the type of work/upgrades/paint etc. on these Fords – saying please fit a 2ltr Zetec 5 speed g/box better brakes better suspension etc.
Another call later was made to the owner to get an exact specification throughout the complete resto. changing specification especially on bodywork/paintwork become will be very difficult say half way through the work, it was decided that a complete bare metal 105E was the way to go, we talked about all the mechanical spec. and arrived at the following – New zetec 2ltr fitted with new ecu twin 45 webbers – modified engine carrier – full recon. long first close ratio 5 speed gearbox – quick shift g/stick – quaife LSD fitted to rear axle- heavy duty quaife half shafts – fully adjustable Gaz front suspension legs – disc brakes on 4 corners – spax rear shocks – new inboard brake clutch pedals – new brake pipes – petrol pipes – master cylinders -modified steering column – converted to steering rack – alloy radiator with new water pipes – new alternator – starter motor – new 4 into one stainless Tiger exhaust system – new wheels tyres – interior new leather high back seats – retrim rear seats to match – new carpets – new seat belts – new steering wheel – fit RPM gauge – oil – temp – speedo.
First job was to strip the car of everything then send to blasters, when we got the call to pick up the 105E, the caller mentioned it was not as complete as when we had dropped it off ? all was explained later as it was now bare metal underside – clearly lots of steel now missing but we had seen this before but actually did not expect it on this car as it did look rather tidy underside originally, carried out by someone was the old trick of tidying up rotten string hangers – jacking points and other sections with body filler then rubbing down and underseal.
We now had the car on the Spital and had rather a lot of welding to do – first cut out a section of tunnel and weld in a larger section for the 5 speed box – new spring hangers – jacking points other panels and various other sections needed doing including repairs to doors wings etc.
All paint was now taken off the full bodywork, repairs to any dents found and sorted – the complete car had 3 coats of two pack primer, the bonnet and boot was put aside until the main tub was finished (Paul in paint shop will only paint these standing up) the primer on body now had around two coats removed on first stage of prep. another two coats then applied and again prepared for top colour (White) the bonnet and boot later go through the same procedure.
Painting in the booth takes around 2 hours for the colour – very light polishing a couple of days later.
Reassembling starts with trail fit of engine and box – engine carrier now in this will give us the position of the rear gearbox mount, the steering column is now modified, front suspension now fitted and steering rack, pedals fitted inside and brake pipes sorted, engine now ready to drop in after having manifold – webbers- alternator fitted – exhaust front pipes fitted – lSD now fitted to rear – brackets are added to chassis to take spax rear shocks – exhaust pipe silencer and brackets fitted – engine is now being finished with coil pack position – radiator – starter – header – engine wiring – and various other smaller parts fitted .
Interior now has in our trim dept. ( Laura ) make a great carpet and retrim the rear seat, front new seats fitted with new mounting points for runners made in our engineering – new belts fitted. Steering geometry is set – engine tested and checked for any leaks and temp. – oil pressure – general checks before the last job a road test ready for the new owner.
