Ford Fiesta XR2 MKII Restoration

Project Undertaken 3rd January 2012 & completed 29th March 2012

Steve's MKII XR2 is semi-stripped out and used as a fun weekend/trackday car. It looks a tidy example, but Steve wants to make the body perfect, and ensure it lasts for many years of driving pleasure!

The first job is to strip the car to a shell. This reveals some localised rust under the bodykit, but nothing too major.

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Next we heat and scrape the sound deadening and underseal as best we can, before mounting the 'shell on a rotating spit ready for blasting.

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Here we see the 'shell after blasting.....

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...... and following a good dose of Zinc Phosphate primer.

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the first area to receive attention is the nearside inner wing, where it meets the 'a' panel. This area is cut out, repair sections made & fitted, and then the small reinforcer piece reconstructed and fitted to complete the job.

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Next the usual rot-spot between the battery tray and inner wing is dealt with. The battery tray is carefully removed, the area underneath repaired, treated with rust-converter and then the battery tray refitted.

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Both valance-ends (wing mounting flanges) are then replaced along with a small repair where the inner wing meets the front panel.

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At this stage replacement wings are offered up to check the fit.

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This XR2 is a stripped-out track car, so while we are working on the metal, we remove all the redundant trim clips and unwanted brackets from the 'shell.

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Moving on to the back end, both sills require repair, both arches are replaced and repairs effected to both rear corners.

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With metalwork complete, we seal the underside seams, and cover it with a good helping of 2k Polyurathene coating. Then we begin preparation work on the rest of the bodywork.

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This starts with initial filler work to get the shape correct, then a coat of 'Reface' spray filler over the areas that need it....

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Which is block sanded and prepared, along with the rest of the body, before applying the build primer.

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The primer is then flatted back and the car rolled outside for a dust off, before trial fitting the panels to double-check alignment before we get to the paint stage (when it's too late!)

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Then it's back into the booth the receive the fresh Frozen White paint!

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with the paintwork complete, we begin the reassembly stage, with a little help from Steve.

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Fast forward throught the details of reassembly, and here is the finished product!

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Media Blasting

Fabrication

Machining

Paintwork

Wiring