1968 Mk2 Ford Cortina Deluxe

1968 Mk2 Ford Cortina Deluxe (26)

This car was purchased from Ebay in 2006 and the blog entries show bringing the car back from being a bit rotten to being a clean, fun driving car back on the road in 2016. 

Fuel supply

08 July 2011 1968 Mk2 Ford Cortina Deluxe 257

As I have now gone for twin 40s the fuel supply, pump etc. will need upgrading. Here I will show you my installation build up.

A selection of fuel parts puchased ready for my installation.August 2008: Here we have the fuel parts ready for installation. We have a roll of 8mm I.D. fuel hose, fuel clips, Filter King fuel regulator/filter with 85mm alloy bowl, pressure gauge and finally a Facet Red Top Competition electric fuel pump kit.
Rear of petrol tank gets a clean up.August 2008: The first part was to locate where the fuel pump was going to go. At some point in the past it appears the car had a towbar. There was a length of angle iron which you can see and a vertical piece which has now been removed. You may see where this was fixed by the hole in the top bar which looks wet as this is where I had sprayed WD40 before removing the nut and bolt (top right). I will use this hole as one of the fixing holes for my new bracket I will make up. Also, I have started to clean up some of the flakey underseal.
Facet Fuel pump bracket ready for bolting back up to Cortina.December 2008: The bracket was removed from the car as the tank needed to come out (pin hole found in tank). This was cleaned, treated and painted. Also, a 2mm thick plate was made to hold the Facet Fuel Pump. This was painted and bolted to the main bracket with 2 x 10mm bolts, washers, spring washers and nylon nuts. This should ensure it does not come loose. The pump mounting rubbers have been bolted up together with the earthing strap.
 

Offside underwing repairs

08 July 2011 1968 Mk2 Ford Cortina Deluxe 262

This is some repair work I was not expecting to do. After some screwdriver proding revealed signs that not all was sound. So, relunctantly I decided it had to be done to make a good job, so it had to come off and a new underwing panel kit purchased. This page will show how I managed to carry this out.

Underwing strut suport not looking good - needs to come out.It started with me starting to remove the underseal. Does it not always!!!! Anyway, there was a bit of a gap between the wing and the strut reinforcement plate. A bit of proding revealed some rotten metal and the reinforcement strut panel could be prised up and down. Not good.
Underwing with all bad metal removed, painted ready for new metal.The underwing panels were removed, cleaned up, metal ready applied and painted with 2 coats of POR15. You can probably make out the bit in black is where the rotten metal was removed which used to be the top of the wing.
New metal cut up, primed ready for welding.A template was made to replace the metal which used to be the top of the wing. Even though the metal plate welded on top by someone in the passed was quite thick I still wanted to replace the metal to make it as solid as possible. The metal was cut out, roughly shaped and a thick coat of weld thru' primer applied for added protection.

A-Post and chassis repairs

08 July 2011 1968 Mk2 Ford Cortina Deluxe 263

A-post and chassis repairs need to be carried out. Both areas are a bit of a mess and need some serious head scratching on how this will be tackled.

Offside A-post cut up ready for fabrication.The problem here is two layers again. Metal is cut out in small areas and rebuilding commences. The bluey colour you see is the inner layer covered in Kurust before being primed.
Offside A-post inner layers protected before fabrication begins.Inner side of A-Post painted to aid protection before outer layer welded in place.
New chassis repair sections from Ex-Pressed Steels.New chassis repair sections from Ex-Pressed Steels. Work can now progress removing the old rusty ones. What is left anyway.

Engine bay bodywork continues..

08 July 2011 1968 Mk2 Ford Cortina Deluxe 237

Inner wings sorted we turn the attention to the firewall area. All seemed ok but......

Nearside firewall.After all the pipes etc. removed we explored the pinky coloured painted area shown in the picture above.
Nearside firewall hole.Surprise, surprise more rust. Just when I thought is was over. Clean up process must begin and affected area cut out.
Firewall.Engine bay stripped of front member, suspension, steering and all cables and pipes. You can just see the rusty area almost cut out on the firewall.

Engine bay bodywork

08 July 2011 1968 Mk2 Ford Cortina Deluxe 254

As the engine is almost complete I turn my attention to getting the engine bay ready. It looked a bit untidy and grubby which is not to my satisfaction. A few repairs need carrying out before sanding down ready for painting in a new colour!!!!

Offside inner wing needing some attention.Offside inner wing looking for attention. The rust has gone through two layers which makes this repair a bit harder to tackle.
First layer of sheet metal welded in place.Rusty area cut out and the first (inner) layer filler piece welded in place. You can also see some POR Strip which has been sprayed on lifting the existing paint away. What a great product this is. Weld thru primer also applied before top layer is welded on.
New sheet metal shaped ready for welding.Top layer sheet metal shaped and treated with Metal Ready prior to being welded in place.

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