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Escort Cosworth Rep

This standard black XR3i is to be made into a cosworth replica by fitting and painting the Autofashion Cosworth replica kit. This is the same kit we supply to hundreds of customers around the world, and provides a good insight into what is required to fit the kit, and the likely final result.

Although the bulk of the kit is pretty much a bolt on simple job, there is one job that takes a bit of time, and thats the arches. These must be bonded on, and it takes quite a bit of time so sort these out.

Because this car is a "sound car" with plenty of stereo we have taken the extra precaution of laminating the shell. This involves stripping the paint, and putting fibreglass laminate on the outside of the shell as in the picture on the right.

Once the fibreglass has cured we then bond the arch over the top.

In this way the panel is better insulated against the stereo equipment that might otherwise crack the joint lines. This process takes much more time, but is worth it for piece of mind.

The bonding process itself must be done quickly because the bonding agent only allows a limited amount of time to bring the two pieces together. 

Firstly (above left) dry fit the items and drill all mounting holes. Only when completely sure may you bond the arch.

Smear bonding paste on the car (above right) and on the arch (left). Notice also expanding foam inside the arch during assembly to improve durability, resistance to cracking and sound deadening

Aligning and bonding the arch is a two person job really, because of the time limitations. Once dry (at least the next day), remove all external fixing screws, and sand the fibreglass and surrounding metalwork very thoroughly - this is vital for adhesion of the filler which is to be used to blend out the jointlines, and edges. This is now a conventional bodyshop job. Fill, sand , prime, flat and paint.

After the primer has cured, more hard work ensues. The arches are sprayed with a coat of black as a "guide coat" or "control coat".

This is then "flatted" back using 400 grit wet'n'dry paper and a rubber block until all the black aerosol has disapeared - this will go through to filler, fibreglass and metal in some areas but if done properly will eliminate ripples, and other defects to leave an ultra-flat finish.

After this stopper is used for minor pinholes and the like and then the panels are primed again.

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Last modified: March 06, 2011                 Click here for Company Details

Tel:-01263 768824 and 01263 583059 for Custom Styling Parts (Fibreglass Parts- bodykits, bumpers, spoilers, vents, skirts, )
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