Sierra estate 24v

turboshed · September 21, 2013, 23:42:43

aha that makes sense,its always something small that cocks it all up.atleast its ok

Dave · September 22, 2013, 09:47:00

Looks like a good job of the welding mate.

whiteestate · September 22, 2013, 20:41:43

Blended the sill in very nicely with the old flap wheel on the grinder no need for filler with that finish well happy feeling more positive with how its coming together

mk22door · September 27, 2013, 12:48:52

Goood work

Lemon-Ade · September 29, 2013, 11:11:09

Looking great Liam your getting close now

it will be worth it mate.

whiteestate · October 03, 2013, 21:13:54

Ordered some more bits this month, Got 2 10" fans for the rad and a full gearbox rebuild kit as its still whining a little bit but the kit is only shy of £100 so not that bad.
Ive had to drop the rear beam off to do some welding just by the beam mounts as its an mot fail there but its getting there slowly and i want it to fly through the mot which I'm sure it will but weighing nearly 3 tonne with the new metal I've put in it we may not be able to move it lol.

whiteestate · October 04, 2013, 11:54:33

My little pile of goodies

Lemon-Ade · October 04, 2013, 19:10:00

It's good when the bits arrive but not when the credit card bill shows up

It's getting back to the same weight as when it left the factory.
Before bits started disintegrating from tin worm lol

whiteestate · October 17, 2013, 21:57:37

Started stripping the gearbox to rebuild it and found a nice little way to remove the rear prop spline by using the rear damper with a couple of spacers and 3 bolts tighten bolts then off she pops not on that tight either.
Crap images its dark lol.

Turboshed has lent me his large 46mm front nut remover but i need to modify it to pull the 2 halves apart.I have the hydraulic front nut which i can secure onto the tool by grub screws and then weld a nut on top of the tool with some threaded bar should do the trick.
don't know how to pull the 2 halves back together may use a little heat and put the input shaft in the freezer first.

whiteestate · October 20, 2013, 17:57:21

Picked up a second hand 4x4 mt75 for £25 on ebay for bits and decided to use the bell housing for my 2wd gearbox as the front of mine was black so out came the drill to give it a clean

Im rebuilding the box as it had a slight whine to it which turned out that the bearing was cracked lol

Getting there with it now all this cleaning is driving me mad

mk22door · October 22, 2013, 15:05:01

I wish i was clever

Good work fella, it'll be worth it.

turboshed · January 14, 2014, 01:45:58

gone quiet on the sierra front, how's it going?

whiteestate · February 09, 2014, 21:53:18

Yeah its been slow I've rebuilt the gearbox but its a little too tight to turn for my liking so I'm going to try and get hold of the ford tools and strip and check again. Its been a busy couple of months been working in Wigan and I've moved into a new house you know how things can slow down and go down the list of priority and the weathers not been too great either !

whiteestate · February 16, 2014, 20:27:07

I have had another attack of welding this weekend which required the removal of the rear beam and fuel tank to weld the inner rear arch lips in and to cut all the rot out of the box section and finish off the rear end of the sills

That only leaves the front passenger side jacking point to be finished and no more welding !!!!

turboshed · February 16, 2014, 22:31:03

Keep on it.not far off

whiteestate · September 14, 2014, 12:18:05

Wow its been a while but things are progressing now.
Ive moved house and I've got a double garage now so plenty of space which was an issue in my single garage in cardiff, also found out I'm going to be a dad so this year has been a bit crazy !

I've stripped the gearbox and checked everything and its all back together and in good order. Just go to trailer the car back to monmouth where I'm now living.

Lemon-Ade · September 14, 2014, 20:04:45

Congratulations on your move and that your gonna be a dad

glad to see your still at it with the car to

whiteestate · September 24, 2014, 08:23:21

Cheers Ade plan to get the car finished well road worthy before the baby comes. I've rebuilt the gearbox with all new bearings and found that my first attempt the rear case lays haft bearing was not in the correct depth should have been 2mm but was slightly more so the gears where touching when all back together now all sorted.

whiteestate · January 17, 2015, 15:48:40

Been having a bit of a break from the car. But I'm back at it after I had no drive after refitting my rebuilt gearbox. Found the issue to be with the second hand ap cossie clutch I used as the centre female spline had separated causing no drive. My new clutch has been sourced and I have opted for a Sachs 2.5 Granada diesel unit at a price of £9.99 lol

All fitted and ready for the box to go back in next week.
I have also poly bushed the front tcas

And adapted my exhaust as it was slightly too short when I made it before

Then just bodywork and putting all the interior back in and time for an mot !

Lemon-Ade · January 24, 2015, 12:54:20

Glad to see it all coming together nicely

are you going to be on the road defo this year?

whiteestate · January 24, 2015, 13:58:48

For sure but been so busy in work though i may have to get in the garage for a couple of nights i think not got much time on the weekends the next few weeks really want to get it done.
Hows your motor when are you going to crank the boost up ?

whiteestate · May 14, 2015, 21:59:28

Little test drive poor vid as the mrs was holding the camera lol !

Lemon-Ade · May 18, 2015, 22:02:33

Nice one mate that's gonna surprise a few people

and lol at your mrs comment

whiteestate · May 28, 2015, 21:12:03

Ha ha she was loving it ! its surprising how quick it is but then there is no weight to it and i have little traction due to the little unsprung weight in the back

whiteestate · July 12, 2015, 20:37:39

Well its nearly done !!! Going in for an mot next month all the welding has been finished just a new battery and wiper blades.
its taken nearly 3 yrs off and on CRY lol but it drives really well and has really good road holding but does let go quite easily too ! lots of grip on the front think i may need to induce more understeer but the handling is very predictable as the lsd does its job i think with an open diff it would be a bit hard to control.
I do love it and I'm glad i chose the estate to do this conversion

whiteestate · July 12, 2015, 20:48:49

The bottom of the wings were rotten so rather than replace the whole wing i cut the bottom off another and welded that in and both sides job done.

I opted to weld this side sill on the front/flat face rather than like i did on the other side on the corner which makes it easy to blend with the grinder which = a lot less filler to blend so lesson learned.
The power boosted brakes are immense too on the test drive they are superb well impressed with the granada cosworth setup on my car

mk22door · July 12, 2015, 22:20:10

Great stuff mate, the end is in sight

(well usually the end of the first chapter lol)

Which way did you do the other sill - what do you mean?

And how do you have your brakes set up? Power brakes without the valve block?

If so that's how I have mine set up (24v)

..and Ive been on & off for over four years I think doing mine

whiteestate · July 13, 2015, 16:37:18

MK22door i welded the first sill to the point where the door edges sort of join the sill this is curved so it is easier to grind the weld back and blend with the use of minimum filler. When i did the second sill i welded it on the side which on a flat edge is quite difficult to get spot on without filler and i found it more time consuming so you live and learn.
Ive still left the valve block on as it still has the rear brake compensator built in to control front to rear bias but i may ditch it in the future and fit a bias valve inside the car.

capri v8 driver · July 13, 2015, 19:37:37

You actually needed one of these ( I dont know the name in English for it) :

You could make a edge on the metal so the new sill sits flat and there is no overlap. Its saves you a lot of work, grinding disks and filler.

They are not to expensive and you can get air powered ones to work even faster.

whiteestate · July 14, 2015, 18:11:27

cheers i did see one and if i ever need to do sills again i will be getting one as it will give you more of a heatsink behind the weld which will also aid metal distortion with the heat.