This MK1 Escort Lotus Twincam is an Australian car imported in by its current owner.
Being an Australian spec car it has a few minor differences in its trim level, the addition of some brightwork to the body and interior differences.
It is to be altered to meet the specification of the UK cars in that it will loose its brightwork as per the UK spec cars but it is going to retain its original green paint.
Although the car first appeared to be in very good condition, after closer investigation it became clear it had been subject to a full restoration previously.
Some areas were questionable so it was decided to completely strip the car to a shell, remove the front wings and have it fully soda-blast cleaned to reveal all its hiden secrets.
As can be seen after removing the front wings it became evident our suspicions were correct, poorly fitted patch repairs to both A-posts were the first things to reveal themselves.
Once the wings had been carefully removed along with the cars remaining trim, glass and running gear, it was then sent away for soda-blast cleaning. This is a process we have started using and although not the cheapest option the process is so gentle, it causes no distortion through heat transfer or pressure to the panels. However the soda alone leaves the substrate to clean as though to speak with no key. It is then blasted again very lightly with a product that gives the metal a key finish.
Once the car had been totally etch primmed the work could begin. The first job was to remove the rear panel so the boot floor could be removed. The original floor had corroded badly on both the drop sides and had previous repairs done to not such a good standard and had perforated in several other places making it unviable to repair. A new floor was supplied by ex-pressed panels. At the same time the lower rear corners were removed from both quarter panels to allow the new floor to be fitted. Once the new floor had been fitted the new rear panel could be fitted and the boot area re-etch primed and sealed to protect it.
Both rear wheelarches had been previously repaired along with lower rear corners and replacement sill skins. This had not been done to the best of standards so it was decided to start again. It also became evident the inner arch or outer wheelhouse as it is known, had been badly repaired so this would also be replaced with new panels. The same was needed to both sides of the car.
Next was to move on to the floor areas and inner and outer sills. To be fair the floor pans were overall in very good condition so it was decided to only replace the area's needed rather than complete floors. The area to the front floor was removed along with the outer edge area to the rear floor. A few repairs were needed to the front chassis sections due to jacking damage not corrosion so again this was done before the new front floor's were fitted as access was available with the floor pan removed. The doors had to be hung on the car and aligned with the rear quarters before welding in new outer sill panels to ensure all the gaps were correct. New seat boxes were also fitted to the car.
Once all the floors, inner and outer sills had been completed the next area was to move on to the A-posts. Again these had been previously repaired to a not so good standard. As you can see once the outer skin of the A-post had been removed it, became evident the inner panel was completely shot. A problem, as this panel takes the hinges so the weight of the door as well. This panel was not available, so a new one had to be fabricated and welded in to position. A very time consuming process as it is vital it is correct as the fit of the door is governed by this. The new outer A-post panel could now be welded in once we were happy with the fit of the doors and front end of the car. Again the same sort of repair was carried out to both sides of the car.
The next area was to move on to was the front end of the car. The inner wings were in very good condition with only attention needed to the rails and front sections. Accident damage to the front of the car previously had been not repaired so well, the front sections to both inner wings needed some quite extensive re-shaping prior to new inner and outer front panels being welded into position. Again all the front end of the car needed to be dry assembled to ensure correct alignment prior to any panels being final welded into position.
Once all the repair work had been completed, it was time to put the car into the paint stage. The complete shell was re-etch primmed prior to being completely primmed with a high build primer. This included the inside of the shell, then the underside and inside were prep'ed and completely sealed. The shell was then prep'ed, sealed and masked in readiness for its new paint.
The car was re-finished in its original colour of Jewel Green. Not a colour familiar on the Lotus Escorts but then this is an Australian spec car so it is original to the car. It was considerd to paint the car in Ermine White as the UK spec cars but then decided it would be best to keep to the original colour. We think it looks great. The panels were then re-fitted to the car in readiness to make the trip back to its owner who is re-assembling the car himself, we look forward to updates on progress of this.
