Escort Cosworth WRC Replica Build Ep6 Changing The Sill And Rust Repairs!

Better Late Than Never As They Say Eh...
This Is The Latest Instalment For The #disascort Wrc Cosworth Replica Build, And You Guessed It, We Find More #rust
I Have Some Decisions To Make On Which Way To Go With This Project Now But Im Hoping You Guys Will Share Your Thought With Me...?
We Still Have Plenty To Do Though So This Episode Is Tackling The Rotten Rusty Sill.
If You're Interested In Buying Any Parts From The Car Please Hit Me Up Over On Instagram @t_devil
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As Always, Thanks For Watching And Hopefully I'll See You In The Next One.
#fastford #ford #milwaukeetools #performanceford #retroford #Cosworth #cosworthreplica #fordescort #disascort #wrcreplica #rs2000 #fordrs #rustrepair #rust #diyfabrication #sillrepair #newsills #r-tech #rtechmigwelder #welding

[@stephenbradley5805]

Weld a sierra floor and inner wings into it, they fit perfectly and that's what ford did

[@Tdevil86]

Not for me that, I can buy a whole e46 bmw for the price some people want for a floor pan now lol

[@neilfairless4589]

Terry, fix the shell so it's a minter and flog it on to get some funds for the Quatsport, maybe even a ramp for the workshop?

[@Tdevil86]

I’m thinking more along the lines of selling the van to be honest mate, iv had my time with it and not really interested in it anymore anyway… A ramp in the workshop would be amazing though, my old bones working on a cold concrete floor sucks lol

[@stephengirling7859]

You never fail to impress me Terry. Great attitude, great fab work and great tunes.

[@Tdevil86]

Thanks dude, glad to hear you like the tunes aswel, it takes me hours to flicking through tunes to find stuff I like haha

[@TheGt5ive]

Funny that when you was talking about taking out the dash, I sat there think that rollcage is going get in the way surely 🤣

[@Tdevil86]

Yeh, was wishful thinking on my part hoping I’d sneak it out somehow 😅

[@robmoot]

thats mega progress Terry!

[@Mk6Escort-RS2000]

Well done Terry .. looks like I'm not the only one with an escort rot box. I've been loosing my mind over the rust on my RS2000 4x4. Mainly I think it's because I'm In a rented garage with no power or space. Thanks for sharing as it giving me a bit of motivation to carry on.

[@Tdevil86]

You’re a braver man than me mate, I wouldn’t be bothering if I didn’t have the workshop space I have, I’d just get annoyed and throw my toys out the pram lol You gotta keep going though mate, you can’t give up! Just think positive and when you drive it again finally all the rusty nightmares will be a distant memory haha

[@dhes2809]

I would love to see you do a similar thing to the quatscort with this but with a different donor. Not that I don’t like the Audi base. I wouldn’t worry about time scales. Your content is addictive and always great to watch so the longer the better really.

[@Tdevil86]

Another chassis swop will be coming once one of these current cars is done, I have a load of ideas for projects yet 🙈 this one won’t be a chassis swop though I’m afraid chap, this one needs to be something different and new things for me to learn how to figure out… we’ll just have to see what happens 😬

[@GeorgeEI7KO]

Rear drive Tel for sure mate. I like the idea of the 370z setup. Fark me Tel that sill was rotten as a pear mate. You're getting the metal bashing skills down to a fine art for sure. Watched the lot from start to finish. Even er' indoors was watching over the top of her phone. 'He's devoted' she said.

[@Tdevil86]

Most would say stupid rather than devoted lol rwd is definitely happening though mate, unfortunately the Nissan 350z idea is a no go though as they’re a little to wide unfortunately

[@johnbevan7157]

Great work on the car, it’s going to be stunning car when finished 😎

[@Tdevil86]

Here’s hoping mate 🤞🏻 it can’t get any worse anyway lol

[@AndrewSmith-iw3xj]

Keep it rear wheel drive and put a sierra flooring in it so it’s more like a cosworth

[@Tdevil86]

I have thought about it but it’s been done to death and I don’t want to be paying Ford tax on everything lol, there’s much better options out there for a fraction of the cost now aswel

[@gazman5980]

Love the episode terry brilliant work m8

[@Tdevil86]

Thanks gaz mate 🍻

[@martynsamsom8237]

Bearing in mind that this was supposedly a “competition” car, the previous owner was using a death trap if they ever had an “off”. Best of luck with your project. I’d go rear wheel drive with the amount of work that needs to be carried out. 😇

[@Tdevil86]

Some people obviously don’t value there life much huh, fitting a cage to a rusty floor pan, not quite sure what they was thinking building this thing lol Great minds think alike though 😉🍻

[@robj1343]

Great work 👏

[@stuarttyson6824]

Amazing work !!

[@michaeljones736]

Nice long video. Amazing attention to detail! Definitely rear wheel drive, how about a crossflow with a supercharger! 😂

[@Tdevil86]

I’m thinking a supercharger, they sound wicked!! Need to decide on a power plant yet, a crossflow wouldn’t quite cut it though lol

[@petermarshall5932]

350z route sounds good.

[@Tdevil86]

They’re a little to wide unfortunately, I was really hoping I could go that way but a e46 is looking like the right direction now

[@paulpobsanderson6219]

Rear wheel drive with a Jag V6 AJ30.

[@bigsquatchsasfoot1964]

Blimey Terry mate you do pick um ! but big respect for saving it What a fabulous job I would have no idea how to even attempt a job like that but you never seem particularly fazed by it , your metalwork skills are something else dude hats off to you . I love these type of vids I don’t really watch anything else ..and I would suggest if your hearts telling you to rear wheel drive it then you should do that now’s certainly the time . Stella job I’m looking forward to the next one and appreciate the uploads ..brilliant 👌👍

[@boostboyfabrications4499]

Buy mk2 escort tunnel panels etc cut floor then use all mk2 zetec conversion bit then a full blown rwd zetec turbo . I would personally use a 6 degree cosworth rear beam with 7.5 inch rear diff

[@Tdevil86]

I’m trying to avoid using Ford parts to be honest chap, the prices people want are just extortionate and unjust in my eyes, e46 bmw is the likely route I’m taking for rwd now

[@neilmaguire5665]

Hi terry, why u so unhappy m8? Its a patch work job n ur doing an amazing job, keep it up wait to its finished n noone will no 😊😊😊😊

[@retrofabrications22]

Had the same issue with my Hero 9 and i ended up formatting the SD card in the camera itself rather than my laptop and it sorted it out so could be worth a try. Looks like the Escort is waiting for an Mx5 rear end....😊

[@TheNorthernmunky]

Awesome video mate, great duration too, made good viewing. I’d like to see some of the fabrication at normal speed so we can see how the magic is done. Love the work mate

[@Tdevil86]

Thank you buddy, I have thought about it, but that piece I made on this video to put into perspective, took me 4hrs or just beating it with a hammer, when it’s sped up and only takes a few minutes it doesn’t have time to get boring lol I’d highly recommend checking out ‘make it kustom’ if you want to see stuff like that in detail, he knows what he’s doing and give good explanations to what/why he does things, whereas I’m just winging it and trying to figure it out as I go lol

[@TheNorthernmunky]

Lol totally understandable and you’re doing a great job mate

[@Tdevil86]

Thanks man, I appreciate that, make it kustom and trev blog are both great channels for learning though, iv picked up a fair bit from watching those guys

[@johnhayles16]

Time for a sierra floor pan to be fitted mate

[@Tdevil86]

Nah not for chap, been done to death and Ford tax is a joke these days lol, loads of better cheaper options though 👌🏼😬

[@billywhizz98]

Brilliant video well done Terry it’s time consuming but worth it

[@Tdevil86]

Cheers dude, it’s all worth while with what I’m able to learn from doing it so it’s happy days really

[@Mr_Rich1899]

Terry, as in my last message, I think you should go 4WD using may be a scooby Impreza turbo wrx, or go big with a Audi S4 QUATTRO B6 4.2 😊😊😊😊 Cheers rich1899

[@Mr_Rich1899]

Also could go audi TT

[@Tdevil86]

I’m already building my other escort on to a Audi s3 floor pan with Quattro running gear mate, haha, this one needs to go rwd I think

[@garytedds141]

Cracking job again Terry you definitely got us hooked it's one of my highlights when your video hits and I would go do the 350z route just a question do you think Stevie Wonder was the last person to do any work on that car

[@Tdevil86]

Haha you’d think so wouldn’t you, some of the work done on this poor old thing is terrible but hopefully I can do it some justice and make it right 🤞🏻

[@kentenbrown8660]

you have to do it

[@malcolmhales8181]

What a shed. Where was it parked, under Eastbourne pier?

[@Tdevil86]

From the state of it you’d think so wouldn’t ya lol

[@stephengirling7859]

Adapt shell for rear wheel drive imo.

[@medievilassassin]

Such masterful work mate , regarding the cad build I like things out of the norm that people are not expecting like a Frankenstein car , put the Mercedes M111 C230 Kompressor engine in it as they are rear wheel drive and super charged , and you can get the engines and diff pretty cheap mate

[@Tdevil86]

I’ll have to look into that, I like Frankenstein stuff hence my Quattro escort I’m also building atm. I have thought about a fitting a om606 merc engine in this, I think a cosworth rally car bellowing black smoke would be hilarious lol

[@medievilassassin]

@@Tdevil86 yeah depends on how far you want to go but with those engine they fetch good money plus it’s about £1,200 to have the injector pump tuned for big power and then there’s is all the other stuff , you could be in a good £7k for a 400bhp engine. C230K you can get for about £300.00 depending if you want it complete , I know a guy with a 245k mile unopened engine whom has boosted it with a giant HX55 turbo at 450bhp, im adding forged rods and a solid copper head gasket with ARP studs to mine.

[@Tdevil86]

Oh really, you have to Chuck a fair old chunk of money into them then, iv not actually looked into properly myself, just thought it would be funny but not at that price lol I’ll look into the c230 option though, iv never dealt with merc stuff before so could be a good thing to learn

[@medievilassassin]

@@Tdevil86 yeah mate I think diesel pump UK do a OM606 ready build for like £11grand You could have a M111 over 500bhp for less than £2K fully forged with turbo and diff and gearbox if you need info let me know as I have just started following you on instagram

[@medievilassassin]

@@Tdevil86 just messaged you on instagram mate

[@gregwooff1]

option 2 and change it to RWD

[@AdamsWorlds]

Brave man! No easy way to do it but getting stuck in, I guess. So many options, just how far do you take it with the other projects. Acid dip/sand blast, or just do what you can see knowing there will be more hiding. With the number of other projects, I'd personally tart it up a little and kick it out the door as a usable classic and take the L on time lost, use the funds from sale for other projects. Might be different for you though, that "lost time" i guess could be fun so not lost at all. :P Oh and for corruption its probably the SD card on its way out. They start to get glitchy towards end of life with storing/reading. They seem to work some of the time only but are recognised.

[@Tdevil86]

I wouldn’t be able to sell it knowing how rusty it is, It’s a death trap really and I know someone would buy it and flip it leaving some poor bugger out of pocket… like me really, I have to much of a guilty conscience for that lol I’ll just keep plucking away at it and see where we end up. It won’t be getting blasted or dipped though, with what I need to remove I think I’m likely to find 95% of what’s hiding anyway and il just fix it when I do 💪🏼 Nice one for the heads up on the card, il go and grab a new one to keep by should mine keep playing up 🍻

[@AdamsWorlds]

@@Tdevil86 ah that’s fair im the same way tbh not wanting to sell something deadly. With the SD card get a fast one they cost a little more but will last longer and be more reliable! And avoid getting one from the net (loads of fake ones about) Argos is a safe bet. I use them in my outdoor CCTV and the cheap ones last maybe 6-8 months with none stop recording the more expensive ones I’ve had about 2 year now and going strong still. :).

[@Tdevil86]

Is there a certain good capacity card you’d recommend, I’m very much a Neanderthal when it comes to technology lol

[@AdamsWorlds]

@@Tdevil86 ha all good yeah your see a little U with a 3 inside it that’s the “class” you want. A Sandisk or Samsung SDXC are the best ones. 100% go to Argos though to save the fake card headache allot of the online ones are fakes reading fake capacity and stuff it’s a well known con. :)

[@patsgaragehnx]

I would choose option 2 and change it to RWD 🤟🤟🤟

[@andymadmac]

I would space frame escort, you dont want to be welding in another floor pan that needs rust repairs, convert to rwd

[@Tdevil86]

We’re on the same page mate, I don’t need anymore rust to deal with lol

[@starfox_wr-45e93]

Id go a half way house between full race chassis and 350z running gear. Its probably worth your time setting up a jig for the 350z gear into mk5 'scort bodies. I could see you completing a run of five of these cars over the next 10 years 😂 I never imagined a restomod company specialising in basemodel mk5's, but im here for it lol Fancy doing a rwd wrc Cabrio for me next? Lol

[@Tdevil86]

I don’t fancy doing anymore escorts, funnily enough though, I said that 3 escorts ago 🤣 350z idea is out the window unfortunately, iv found they’re about 3-4” wider than the escort after doing some research which is no good, Nissan s14 or a e36/46 bmw are pretty dam perfect though 🙈😉

[@starfox_wr-45e93]

@@Tdevil86 heh, it's a disease being a car person, Nobody tells you that part going in. 🤣 Given those choices, e46 is probably the best bet imho (and also the worst funnily enough. Lmao) it's the Cheapest and most available. Best chance to correct the all too common and dreaded cracked subframe issue they all suffer from is when you have the whole this seperated from the rest of the body on a pallet. Ideal 🤣 aside from the subframe issues, the e46 is probably the best chassis of those three in almost every way.

[@starfox_wr-45e93]

@@Tdevil86 just to add, there will be awd options with the later bmw chassis too btw, which would be pretty awesome. 8hp trans, turbo lamik controller, x-drive transfer case and front diff if you're feeling really adventurous 😉

[@Tdevil86]

Yeh Iv heard about the cracking issue’s, also suspension tops rusting out etc, in a ideal world I’d like to use m3 parts but it’s all down to cost at the end of the day, unfortunately budget isn’t endless so I think start with a e46 and maybe upgrade later when funds permit… Car addiction is definitely worse than drugs I think, atleast people feel abit sorry for druggies, people just think you’re stupid when it comes to cars 🤣

[@Tdevil86]

What a turbo lamik controller?

[@leuvenlife]

rwd, proper rollcage, alloy tank, batt in boot, roof vent and something like a supercharged zetec ..?

[@Tdevil86]

All of that but a supercharged something else possibly, something that’ll give me abit more grunt 😬

[@leuvenlife]

@@Tdevil86 Yeah, yeah.. I can see your thinking... ;o)

[@paulriggers1558]

trying to think budget -friendly here - give it time-out in a corner, concentrate on the quat for now then space-frame a twin turbo audi lump in the back... [there's a bloke with one in a mini] escort RS 200 ? [+ have a night or 2 off]

[@Tdevil86]

A twin turbo Audi engine in the back of a mini? I need to see that! It sounds nuts! I have actually had a few evenings off this week, and this weekend infact, try and recharge the batteries a bit haha it does certainly get to you working all day then doing an evening shift pretty much every night. I’ll keep plucking away on this until dean wants the space back and then it’ll be going back into hiding I think, like you say Paul, concentrate on the quattscort for the minute then come back to this potentially, I don’t have the funds to carry both these projects through at the same time unfortunately, might even be time to sell the van to be honest…

[@paulriggers1558]

he's called matt green, [MG] another nutter i watch...@@Tdevil86

[@Tdevil86]

I’ll try and check that out later, been a busy week so time to unwind with abit of KZbin tonight I reckon, see what other silly ideas I can get inspired with lol

[@neilmaguire5665]

Can u not tube it with backseat terry? That would be cool but keep it ford m8, maybe 4wheel drive? 😊😊

[@Tdevil86]

You probably could but it would be a contortion job getting in the back lol It won’t be staying Ford I’m afraid bud, Ford tax has killed the Ford scene for me

[@nikosgalis6007]

Terry why don’t u do it like ford did it? Chop a sierra to keep the floor, shorten it by 5cm and body swap the escort body on it.

[@Tdevil86]

I have considered a Sierra but it the Ford tax that comes with it unfortunately, I can get newer parts from other cars for a lot less that’ll ultimately make this thing drive better anyway. I love my Old Ford’s but Ford tax has ruined them for me abit now…

[@nikosgalis6007]

@@Tdevil86 in my country sierras are very cheap. U can find a decent shell for around 1000€. Used parts are dirt cheap! That’s why I dropped this idea.

[@Tdevil86]

Unfortunately here in the uk everyone thinks they have gold and want crazy money for parts, not just Sierra but most Fords in general now, even rot sapphires are going for 2.5k or more If you have rhd sierras you should import some over here, you’d be rich in no time haha

[@nikosgalis6007]

@@Tdevil86 only lhd in Greece. Rhd cars are even cheaper because nobody wants them here.

[@Tdevil86]

You should start importing to the uk, you’ll be rich in no time lol

[@adrianricketts8884]

Would you consider making it into a escort cosworth engine and box

[@Tdevil86]

I’m afraid not, the money cossie engines and box’s command is more than I’d be willing to pay

[@iand299]

350z but shelf this project til the quatt is done.

[@Tdevil86]

350 is no good after all, it’s to wide unfortunately, but this will be getting shelved shortly anyway so I can get back into the quattscort, I’d like to get that shell fully together before going made on this thing

[@davelees7066]

How about Mazda MX5 NC 2ltr 6speed +LSD. Still Ford engine

[@Tdevil86]

I already have a plan to get another mx5 track toy down the line so I would use one for this really, at this point a e46 bmw is looking like a good candidate for suspension setups etc

[@thumperstu]

rear wheel conversion....

[@julias-shed]

Blimey has this car been parked in the North Sea? 😮 should make good content 😀 I'd go full spaceframe as you can get advice from next door. Plus it's different to the other escort project 😜

[@Tdevil86]

You’d think so wouldn’t ya lol worse than most cars Iv bought from down on the south coast where I live lol Space frame is definitely winning my vote atm, iv always loved the look of tube work and always fancied having a go myself, and yeh, thankfully Iv got Jon around to advise on that aswel which is a bonus!

[@julias-shed]

@@Tdevil86 cool look forward to seeing what happens 😄

[@alexdarcy3121]

Would a 350z be too wide? What about an mx5?

[@Tdevil86]

It is unfortunately, I was meant to mention that before finishing the video 🤦🏼 they’re actually 3-4” wider so that ideas a no go, a Nissan s14 or bmw e36/46 however is neigh on perfext 😬 i want to get another mx5 track car at some point so I wouldn’t use that platform for this, they’re wicked fun on track though!!

[@ektrolleyboy]

Needs stripping and dipping. No other way for a Ford to be certain of what you’ve got.

[@Tdevil86]

I’m not brave enough to dip it, I doubt I’d get anything back lol

[@johnhayles16]

I need a boot lid if that's for sale mate please 🙏

[@Tdevil86]

This ones not in the best shape unfortunately mate, needs a few repairs and doesn’t have the screen, you’re welcome to come and take it though if you wana fix it, it’ll only go on the scrap pile otherwise

[@johnhayles16]

@Tdevil86 where are you in uk mate? How do I get hold of you please

[@Tdevil86]

I’m in eastbourne mate on the southcoast, usually miles away from anyone lol

[@jondrew6761]

Scrap it, you have got enough work to do on the other one!

[@Tdevil86]

Blasphemy! Where’s your sense of adventure 🤷🏻😅 but nah, I can’t scrap it, it’ll live again 💪🏼

[@KevinSimpson_MTB]

Good long video Terry. You probably need it like a hole in the head, but my vote is tube chassis and rwd 😁

[@Tdevil86]

Man after my own heart! Tube chassis is winning my vote atm!

[@neilmaguire5665]

Can I have the steering wheel plz 😊😊😊

[@Tdevil86]

£25 and it’s all yours bud

[@stu9070]

Scrap it

[@Tdevil86]

No chance, there’s still life in this thing yet lol

[@capt_flapper]

Restore it to road legal and raffle it

[@Tdevil86]

It’s to much work to risk putting up for a raffle now unfortunately, it’ll be just as much work restoring it as converting to rwd realistically, the floor and chassis rails all need replacing to make it mint and I’d rather invest my time into making it better if I’m honest

[@jongillman6006]

Don’t waste your time on a rot box…

[@Tdevil86]

It’s not time wasted Jon, it’s helping me learn my way with metal work and saving a car in the process, it’ll all good fun mate 😬

[@paulshockieuk2651]

This needs a dip to show all metal..like this it would hide it all

[@Tdevil86]

Only thing that puts my off dipping a car is not knowing what hidden bonding and seam sealers been stripped off aswel, cutting it out and finding it as I go means I can add it all back as I go…