Series One Rebuild (Carl's Ford)

Carl (build documented by his mate) · Ford Sierra/Escort (Series One, model not explicitly stated)

4-page write-up

series one rebuild

Read the full write-up at series one rebuild ↗

A friend-built Series One Sierra/Escort rebuild, from bare shell to running turbo car

This long-running forum thread by reborns1 documents a complete bodywork and mechanical rebuild of a Series One Ford, owned by his mate Carl. The car was stripped to bare metal, had extensive panel and chassis welding, a full repaint, rewiring, suspension powdercoating and turbo engine fitment, with progress slowed repeatedly by parts hunting and life getting in the way over several years.

Specs

As stated in the original write-up.

Brakes: Cosworth brakes fitted all round
Steering: Steering rack fitted for rolling, later planned replacement
Fuelling: K-Jetronic fuel injection

Parts used

Parts named as used in the original write-up, grouped the way the Parts page groups them. Where one of the shops we index lists the same thing for this car, it is shown underneath with a link to the shop.

Fuel & Ignition 1

Replacement fuel tank
Sourced and refurbished after the original was ruined by shotblasting

Suspension & Steering 1

Mk3 handbrake cable
One-piece correct cable eventually sourced after supplier errors

Brakes 1

Cosworth brakes
Fitted all round during suspension and driveline reassembly

Body & Trim 1

3M Bloodpack stonechip
Used as the stonechip coating on the underbody/body

Electrical 1

Replacement dashboard
Near-perfect dash bought on eBay after the original was found damaged

Photos

2 pictures collected from the write-up, in the order they were posted, shown from series one rebuild. A picture opens larger here, with the way through to the page it is on.

reborns1 · May 11, 2022 | 01:48 AM 1this post at series one rebuild ↗

reborns1 · May 18, 2022 | 11:34 PM 1this post at series one rebuild ↗

How it was done

Starting condition

The car belonged to Carl, who bought it around two years before the thread began and left it sitting until work started. An old photo showed it in its original, newer condition before the rot and modifications that had accumulated.

Body and chassis repairs

Extensive sections were cut out and replaced: front panel, crossmember, flitches, scuttle, wings, A-posts, sills, wheelarches, floor, chassis and bulkhead sections. Suspension was temporarily mocked up to gap panels correctly before the shell went to the bodyshop for priming and paint.

Paint

The car was primed, flatted, and painted white at the bodyshop, along with bumpers, mouldings, mirror caps, grille and spoiler, with help from several friends during a concentrated weekend push.

Wiring and interior

A damaged wiring loom was rebuilt by combining two looms. Interior trim, headlining, sunroof, seats, seatbelts, carpet and dash were progressively fitted, with mismatched alarms removed and wiring reverted to standard.

Mechanical reassembly

Front suspension components were powdercoated and refitted, a new fuel tank and handbrake cable were sourced after setbacks, and the engine and gearbox, driveshafts and Cosworth brakes were installed. Cooling, clutch, throttle and brake pedal systems were connected.

Progress so far

By 2014 the car was reported running, though not confirmed finished. A 2022 update included a current photo of the finished-looking car, described as still looking fresh five years on.

A summary in our own words. The full account, with all its detail, is in the original write-up: read it at series one rebuild ↗

Worth knowing

Soak seized suspension bolts periodically beforehand so they come free more easily later
Running wiring through a bench grinder wire wheel strips coating so solder flows properly on tailgate loom repairs