anglia4's anglia zetec

[anglia4]

Thought i better start a thread on here for my project.

I've been chipping away at it for a while now, when i bought it it was mostly stripped except for the running gear which was a 1300 escort engine.

i spent a few months cutting out all the rust, i've never done any work like that before so i've just been learning as i go, and my welder is sh** which makes it a bit harder but im getting there.

i've got a 2.0 litre zetec engine mocked up in it at the moment, i've also just picked up a megajolt ignition and a set of quad carbs from a yamaha R1. I've started making a custom exhaust manifold which is coming along pretty well. This combination should be good for about 150-170hp

sitting in my shed next to the car is a set of mk2 cortina front struts which need to be modified to fit the anglia and converted to coil-overs. (does anybody have some second hand strut inserts from a mk1 capri spare??)

i also have a type-9 5 speed which will eventually make its way into the car but for the moment it will only get the 4 speed as i can't afford to do the 5 speed conversion at the moment.

for the moment the diff will be standard but i also have a disc brake LSD from an EA falcon which will get shortened down when money allows and the anglia diff breaks

most of the metal work on the body is done, and i am hoping to get the car running by the end of the uni holidays so i can get it from new plymouth to chch.

this is when i first got it (looks similar to now overall)


with the zetec


with the new headers tacked up


long way to go yet, its nearly ready for sanding down and shooting in primer to start the tedious body work...

still got to modify the sump, fabricate a water rail, rebuild some decent engine mounts, finish the exhaust, build an inlet manifold, hook up the ecu, tune it, modify the struts and suspension, sand it, primer it, fill it, paint it, cert it, wof it, and then enjoy it

[anglia4]

Now that im home in new plymouth for a bit i managed to get into the shed this afternoon.

re-aligned the anglebox's position in the shed

i had cut the rear bumper mount rail/valance thingy off a while ago, i had been buffing the paint off to bare metal and found that all the metal disappeared... so i cut off what was left and got another folded up where i used to work.

standing the car on its edge however i have now found more rust in the seam of the boot floor

so i cut a big hole in the floor (no pic of that yet)

also found that the bumper mounts themselves are totally shot

so i cut them off too, i've just spent the rest of the evening starting to unpick whats left of the section of boot floor that i cut out.

tomorrow im going to go and get a spot weld drill to make things alot easier. Then i'll start on some welding with my piece of crap mig welder.

[anglia4]

i borrowed a mates spot weld removing drill thingy today, saved soooo much time.

I unpicked the seams on all the parts around that rear valance area and found ALOT more rust

i cut the bumper mount off the right hand side and found the chassie rail to be full of old mud... had to ask the question "where the f*** did that mud get in?" so i went along the rail with a screw driver and right where the tyre would throw dirt at it, the screwdriver dissapeared through the underseal. big hole...

and then once i got the rest of the bumper mount and valance cut off i found a piece of tin that was riveted over the end of the valance, so i ground off the rivets and found even MORE rust...

so now with all the rust cut out along the valance area and all cleaned up ready for patch panels

as you can see i have spent lots of time on the end of my grinder today

i have also decided to get some dry ice and get ALL the underseal off, i want to know what other big rust holes are hiding underneath it, hopefully not too much. the car will be getting completely bare metalled now as i don't want any bubbles coming out of surprise bodgey repairs that were done by other owners.

i've got patch panels made up for all the boot floor holes now too which i will fit up tomorrow.

[anglia4]

managed to spend a whole bunch of time in the shed yesterday and got a fair bit done.

managed to get two of the three big holes patched, the other will have to wait till the car is on its other edge to get access for welding.

also removed the diff assembly and cut out the rusty section of chassie rail and started to fab up the replacement section

hopefully i'll get into the shed for a bit tomorrow and finish that chassie rail and then rip into making up new bumper mounts

[anglia4]

got my patch panel pade up for that chassie rail.

I'm very proud of it, its the best bit of fab work i have ever done! and i even managed to get a halfway decent weld out of my mig

also started to fab up the new bumper mount and chassie rail end almost finished it and ran out of bloody wire!!!

making steady progress anyway, keep getting distracted by dads race car project...

[anglia4]

starting to get a bit dis-heartened with this project at the moment...

started stripping back all the underseal and found more rust. a whole bunch of little 2 or 3 mm holes in the chassie rail on the drivers side from the steering box back to the gearbox mount.

i also found a hole lot of rust in a box section that goes across the front of the car behind the front lower panel. Ideally i would unpick the front panel to get proper access to repair it but that is along way beyond my skills so im not really sure what im going to do there.

I got some dry ice for getting the underseal off but i don't think its really helping all that much. some of it seems to still be really hard to get off and some of it comes off easy.

there are places where the underseal has been covered in oil for a long time and it has kept it really soft and damp, this is where the rusty spots seem to be as well.

lots of work to go anyway, i'll be back in the shed later tonight so i'll take some photos

[anglia4]

managed to get a fair bit of the underseal off the inner guards on the left hand side of the car and a few areas on the underside of the floor.

found yet more rust

and even more rust, thats the area that i have no idea how i am going to fix

made a hell of a mess of the shed floor

[anglia4]

started to buff back the rust on the right hand chassie rail between the steering box and gearbox crossmember and it is looking a bit like swiss cheese. might have to start cutting bits off my parts car soon was hoping to keep it pretty much complete but doesn't look like that will be the way now.

am thinking that the rear half of the donor car wil become a trailer with a bbq in it in the future. should be mint

[anglia4]

spent a bit of time in the shed this afternoon and got a wee bit done.

got sick of the mess in the shed with all the underseal that i chipped off so i had a clean up:

before:

after:

got as much welding as i could done on the right hand chassie rail and bumper mount, will finish it off when i flip the car on its other side.

started welding in the corner plate on the left side of the car as well, same deal though, got as much done as i could before the car gets flipped.

found a bunch of rust in one of the chassie rails nearer the front

repaired a little bit of the chassie rail:

im fricken stoked with how that repair came out, the flash on the camera shows it up a bit but you can hardly see that i have been there.

I read a bit of a tutorial on the net today about welding and it helped heaps!

[anglia4]

started today by pulling off the sway bar mount since i wanted to rebuild the chassie rail underneath it. once i got it off i found a horrible looking previous repair that had gone all rusty and just looks like crap:

so i went ahead and cut the bugger off:

which then revealed another crappy repair:

the steel that has been used for this repair has gone all rusty and it is not a flash job anyhow... so i cut the bugger off:

and made up a patch:

tomorrow when i manage to pick up the spot weld drill off a mate i will unpick the lower grille opening coz it needs some serious repairs...

and so that i can get at this:

its scary cutting chunks that big off the car!! i'm going to need to pick up more panel steel tomorrow i think...

[anglia4]

alrighty time for a bit of an upate

i have unstitched the lower grille opening to get at the radiator support rail behind it. I found that the grille opening was a bit rusty too so i made up a new one, this also got rid of the crank handle bump that they have.

this is the lower support rail that was rusty as you can see

i also put back together the inner wing and its parts:

i put the rest of that chassis rail back toghether now too but i don't have pictures of that yet, i also have put the new radiator support in and the new grille opening and it has all fit together quite well.

[anglia4]

Just a few pictures to put up

Thats the completed chassis rail and swaybar mount

there is the finished grille opening

I then moved on and tackled one of the larger spots of chassis rail rust:

It came out looking sweet, im getting pretty good at this stuff, every patch i do seems to be better than the last, especially looking at my first patches!

next i tackled my first bit of sill rust

and since then i have turned the car up on its other side today and have finished most of the welding on all those repairs. one more major part to fit and then just alot of scraping and buffing to get it back to steel and the underside will be ready for prep and paint, with the exception of the enlarged trans tunnel which im yet to do. Im moving back to christchurch in a week which means progress will halt for a long while again. i was hoping to get the underside finished by then so that i could tow it back but doesnt look like it will happen now after finding all that rust...

[anglia4]

Alright time for a bit of an update, i've finally managed to get home from uni for a couple of weeks and i have been stuck into the little car.

stripped off a bit more underseal

im getting pretty sick of stripping that underseal and im pretty confident that i have found all the rust now, i've got the floorpans all stripped and have the arches left to do which is the hard bit. Im kinda thinking i'm just going to give it a good waterblast and then POR15 the floorpans and leave the arches with underseal.

i finally managed to get to a point where i could re-attach the rear bumper rail part which i'm stoked about

Here is where the bumper mounts come through

Check this out for panelcraft! i'm really happy with how that turned out

Put the petrol tank in to make sure it still fit as the straps mount to that rail

took out the last major bit of rust on the car next, it was above the rear windscreen and came out pretty good

I put the car back flat on the ground and then had a look at how it all came out, when i find some bolts i'll trial fit the bumper too.

I fitted the new 5 speed up to my zetec and put it on the crossmember on the floor... couldn't help but take this pic

then the dog came over for a pose

putting the new box on highlighted a bit of an issue, the starter motor fowls on the crossmember so now i have to move the engine up about 15-20mm.

picked up the front of the car with my hoist

put the fitted-up subframe under the car, looks wicked, i reckon i should rethink the whole project and just make it into a funnycar

heres how the floor looked at the start of the night

and heres how it looked at the end

My new wheels turned up the other day and they look tops! 13x7 for the front which is borderline for an anglia, and then 13x8's for the rear which are seriously borderline. im thinking i might man up and shell out some money to shorten my fairlane diff though and that should help make them fit.

anyway for the moment i will have to make do with it looking like this

I love those wheels!

[anglia4]

alrighty, been a while since i've updated.

Have managed to get a couple of things done over the last few days.

Got my revised engine mounts welded and fitted up, just have to trim them to make them look pretty and give them a coat of black zinc.

They are way better looking than my previous attempt and allow more space for the starter motor.

I also managed to get my gearbox mount all made up, its using the cross-member from an automatic 95 mustang i made some drop mounts to fit it all up.

stood around scratching my head for F-ing ages trying to figure out how i was going to go about finding the right shape for my gearbox tunnel and in the end decided to mock it up with welding wire to get the measurements.

And then measured it all up and marked it out on a sheet

Will take that out to dads work in the morning and cut and fold it up. fingers crossed it fits! i got 3 spare sheets though so no biggie if i stuff it up.

[anglia4]

And the few other things i managed to get done while i was at home.

Tunnel all folded up

Hole cut out much biggerer

sat up in place

end folded down

And welded up

I then decided that the floorpan was looking way too complete and cut another bit hole to do some minor rust repairs

repairs to the sill

all patched and welded

and again on the other side

and found all this in the sill, its not even half, most of it is spread around my shed/face from the duster gun

sill all cleaned out of all the mud

and welded

[anglia4]

Was like christmas today, opened a bunch of stuff from the states.

Got my R1 quad carbs and also my M90 supercharger, it came with intercooler and pipes from the thunderbird it came out of.

I have no use for that 'supercharged' pipe but will have to find one coz it looks awesome.

exciting stuff but still no time to actually work on the car

[anglia4]

Update time cos I'm sick of studying and am running out of things to procrastinate with.

A few months ago I snuck the little orange beasty into dads mustang shed so I can use the air tools and the 3 phase mig we now have.

And then decided that before I get too carried away with things, I should see if the doors actually fit after my panel repairs... they don't

This is the first time the car has had a door on it since I bought it

There is no panel gap at either end, I went through my stack of doors and found the one that is in the best nick that fits nicest so I will work around that one.

I think the car must have had a nudge in the side somewhere at some stage, the outer sill has a gentle curve in it so it doesn't line up with the lower edge of any of the doors, and the hinges in the a-pillar have moved back slightly which is why the door doesn't line up properly at the back.

It doesn't line up properly at the front cos I didn't think too much about it when I was doing the front guard patch.

So i've cut the front guard patch off again but I cut away more of the lower guard this time cos it had a rough previous owner patch in it, and sure enough found another rust hole where the a-pillar meets the lower sill. Easy fix but I don't have photos.

I might buy a new outer sill for it to try and straighten it out, and maybe a guard patch panel too. (all available from the uk)

The panel gaps on the hood suck. Would it be better to try and pull the whole inner wing across on a chassis machine or cut and extend the hood to meet it? (don't worry about the top-mount moving and fucking with the geometry because I'm going double wishbone and won't be using it)

I've also spent quite a bit of time writing a matlab program to help design the front suspension

Its a work in progress and i think it still has a few bugs as some of the outputs still don't look quite right, but its getting there.

And I have also made a start on modelling some of the bits I have already to design the rest around

The floorpan model is reasonably accurate, at least within angle grinder tolerances

Its lacking a bit of detail around the back and the strut tops but alot of that will be cut out so it doesn't matter anyway

discuss viewtopic.php?f=18&t=20751&hilit=anglia4%27s+anglia+zetec

[anglia4]

Can't believe I'm finally making an update to this!

Finished repairing the A-pillar

I've rebuilt quite a bit of it now.

Feels good to finish another patch and have it looking good. Might redo the front of that sill though, reckon I can do it again better haha.

Also thinking I might build a rotiseree.

Hopefully there will be more updates soon now that I am back in the same town as my car!

Discuss //oldschool.co.nz/index.php?/topic/26447-anglia4s-anglia-zetec/

[anglia4]

Cut off an old repair this evening.

I bought a spot weld drill from ebay, makes this job so much easier!

So now there is a big hole. One of my mates has some sheet metal benders that I'll use to fold up that section of upper guard. I chose to make the cut below the line of spot welds so that it will be easier to clean up with the grinder and it will be easier to hide the join.

At some stage, someone has had the whole guard off on this side by the looks. I think it has also had a whack in this corner and hasn't been straightened properly, the panel gap on the hood is pretty big. While I've got a lot of strength missing from this area I'm going to try and pull it straight.

I'm thinking I'll brace the chassis rails together and pull the top of the guard in from the chassis rail on the opposite side.

Hopefully that will work out!

[anglia4]

I haven't got any further with the body work since the last update but I bought some seats of Lee a few weeks back.

Sat them in there last night and the gravity of just how small this car is started to sink in...

Will probably run them quite close together to give plenty of helmet clearance for a roll cage across the top of the door, then maybe have a hydraulic handbrake on the door side of the seat... maybe... dunno, just thinking out loud at the moment.

Duscussion thread: //oldschool.co.nz/index.php?/topic/26447-anglia4s-anglia-zetec/page__hl__%2Banglia4%26%2339%3Bs+%2Banglia+%2Bzetec