Diff & Brakes

Have been cracking on with lots of little jobs in preparation for getting the car back soon. Completed building up the diff. Fitted up a new bias strap for the rear handbrake mechanism. The old one was pretty much stuffed so I drilled out the rivets and disassembled the brackets on each end. Sanded them and painted them with etch and then gloss black engine paint. Finally I bolted up a new replacement rubber piece that I bought from the UK Owners Club. Looks really good fitted. You can buy replacements that look close to the original but they are $70 and while this one is accurate but not quite concourse, I’m pretty happy as it only cost about $5. Installed a new rubber bush for the handbrake lever, greased it up and installed my bias bar, that has been powder coated, with new nuts and washers. I had new brake lines made up a while ago as a copy of my old brake lines. The back one across the diff has some bends in it which I’m not really sure why they are there. I copied how they were bent when I took them out but I think I’ll get a new one made after I’ve put it in the car as I think I can get it a bit neater. I’m also missing the clevis pin that holds the brake bar in so will order a new one shortly. A couple of areas need a touch up with some black paint but really it’s all as good as new now.

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Rear Brakes Completed

So, I finally got round to completing the rear brakes. Was a bit of fiddling around getting springs back on and a fair bit of sanding out of holes to remove paint and powder coating but everything appears to be operating as it should. I’m not sure how the self adjusting mechanism works, I guess I’ll find out the first time I go to stop!

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Rust Repairs

Dropped in to Warwick’s on the weekend to check on the progress of the body work. Warwick has been busy and all the rust repairs have been completed and the new panels from Ex-pressed fitted. A couple were a good fit but most required a fair bit of fettling to fit well with some of the curves incorrect or length not quite right. Warwick has also gapped the front doors and they look absolutely spot on. This car will certainly have better gaps than Ford ever managed from the factory and a lot of work has gone into extending some of the panels and shortening others to get them perfect. All the joins have been welded and lead filled. I don’t think there are many panel shops still around that would lead fill but the result will be a car that should still look terrific for decades to come without the fear of rust bubbling to the surface.

 

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Diff and rear brakes

Started building up the rear brakes on the diff. Was a bit annoyed that when I pulled all my brake parts out that the Cortina Club had sent me one correct and one incorrect rear brake cylinder so I could only build up one side. Unfortunately I didn’t take any photos of the brakes when I pulled them apart so it took a bit of fiddling around at first as it’s been a long time since I built some rear drum brakes. Eventually things fell into place and I just need to order another brake cylinder and the diff will be ready to install when the car arrives for assembly

 

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Body Shop

The car has now been at the body shop for a few months now. It’s been fully stripped. After inspection we determined that it would be best to order some new panels so I made a list and purchased a bunch of stuff from Expressed Panels in the UK. After about a month they arrived and are now at the workshop being fitted up.

 

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Body Work

It’s been a while since I’ve posted as we’ve been selling our house. Today though the car headed off to the body shop. The plan is to sand and dust blast the body completely, make any repairs and then paint in the original silver metallic grey. First up will be the interior, underside and engine bay before it will come home and I’ll fit up the running gear before it goes back for the exterior.

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Suspension

I had Suspension Concepts at Wyong reset a set of rear leaf springs. They inverted the top leaf and added an extra leaf. It should sit a few inches lower now. They gave them a coat of paint but They still look pretty shabby so I think I’ll get them blasted and will paint them properly. They also hooked me up with a set of lowered King Springs for the front. I wanted to go a touch lower but they advised against going any lower on the standard setup. If I’m not happy with this setup I’ll put the standard GT struts in the cupboard and have them make me up a set of coilovers. I also ended up getting a set of adjustable strut tops. My original plan was to install rebuilt originals (which I have), but Greg from Suspension Concepts was very persuasive about the benefits of dialling in some camber and caster. Again if I’m not happy it’s an easy swap to put the standard strut tops in.

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