xr2 rebuild 2 litre made me mind up now 22/3/12
Re: run around / project, mk2 xr2 updated 10/10/09
looks like a good project, should be a beast when done 

- corrupt_panda
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Re: run around / project, mk2 xr2 updated 16/10/09
hope so mate
update, some thought i would never get round to it and im sure clark (knuckles) didnt belive me when he called today
but the pics will do the talking


had the nipper helpping today too





i know everyone like to tak the pi$$ about my fag breaks, yes im smoking again have been for a while, but still


nipper getting stuck in, good lad, more fag breaks for me!


update, some thought i would never get round to it and im sure clark (knuckles) didnt belive me when he called today


had the nipper helpping today too





i know everyone like to tak the pi$$ about my fag breaks, yes im smoking again have been for a while, but still


nipper getting stuck in, good lad, more fag breaks for me!


- jayrs
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Re: run around / project, mk2 xr2 updated 16/10/09
- dangerousdave
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Re: run around / project, mk2 xr2 updated 16/10/09
nice progress mate don't take long to pull to bits do they
keep up the good work


- rsonblackwheels
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Re: run around / project, mk2 xr2 updated 16/10/09
A decent update at last
You and Jon both taking your motors apart, must be something in the air over there mate

You and Jon both taking your motors apart, must be something in the air over there mate

- Turboboy67
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- rsonblackwheels
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Re: run around / project, mk2 xr2 updated 16/10/09
dave and rsonblackwheels , long way off mate, body work first, the main part is fine, underside is sound, well done some welding to the front floor when i got it rest is fine, well looks to be i'll find out more when its on the spits but thats a while away yet, before any panels are cut off, the bonnet will be sorted as im having it opening the other way like normal cars lol, and the doors will come off and the hinges overhalled as the mk2 suffers from worn hinges and the doors drop when they open, this one isnt too bad, passanger side has tiny bit of play hadly anything tbh, drivers door is worse so they will be sorted and put back on so i have lines to work to when the wings etc come off.
the bonnet will be done and put back on before wings come off so i have lines and gaps to work too, again for when the wings etc go back on.
and yes, hes my new apprentice, does what his told when his told and dont want paying!
well not yet anyway
shaun, indeed mate, there must be something in the air, not wasting time,
car was moved out so the tyre machine could be bolted down to change a couple tyres for my dad and another strip light was fited up before the car went back in, oh and spent a hour this morning sorting the rest of the bench and getting a aerial set up so i could get the radio working, cant be working with no tunes!!!
so didnt really get crtacking on the car till after lunch time but was still back indoors with cup of tea just after 6
plans for tomorrow is nothing majour, strip the rest of the bay, get ar$e in the air and strip off what ever i can, i want the car a bare shell asap tbh and ill bung some wheels on a pallet and pop the shell on the pallet at some point untill i get enough metal together to make the bench/frame for it to sit on, thats about it tbh, dunno how much time ill get on it this side of christmas, got maybe 2 or 3 weekends on it, rest of them im on standby so them weekends will be a bonus if i get anything done so if i can get it to what i class as a good point, i.e as stripped as poss then its all good
the bonnet will be done and put back on before wings come off so i have lines and gaps to work too, again for when the wings etc go back on.
and yes, hes my new apprentice, does what his told when his told and dont want paying!
shaun, indeed mate, there must be something in the air, not wasting time,
plans for tomorrow is nothing majour, strip the rest of the bay, get ar$e in the air and strip off what ever i can, i want the car a bare shell asap tbh and ill bung some wheels on a pallet and pop the shell on the pallet at some point untill i get enough metal together to make the bench/frame for it to sit on, thats about it tbh, dunno how much time ill get on it this side of christmas, got maybe 2 or 3 weekends on it, rest of them im on standby so them weekends will be a bonus if i get anything done so if i can get it to what i class as a good point, i.e as stripped as poss then its all good
- jayrs
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Re: run around / project, mk2 xr2 updated 16/10/09
great progress
thought u had forgotton about the xr2
you going injection or carb with the 2.0 ??
finished mine today but realised how poo the brakes are
looking forward to more updates

- jonboisescort
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Re: run around / project, mk2 xr2 updated 16/10/09
cheers dude, going injection mate, althought after starting and driving the xr2 after 6 months and seeing just how good the engine in it really is i am tempted to keep the cvh lump lol, but i wont
- jayrs
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Re: run around / project, mk2 xr2 updated 16/10/09
you wont regret putting the 2.0 in
my cvh was running great felt such a shame to rip it out
my cvh was running great felt such a shame to rip it out

- jonboisescort
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Re: run around / project, mk2 xr2 updated 16/10/09
i wont be dumping the cvh engine thats for sure, i drained the water from it and it was as clean as the day i put it in a couple years back, the cvh engine is just great condition, ticks over nice, its quite, even after starting up the tappets were quite, even the ones in my rs make a bit more noise and there fcuking nyon brand new!
mind you, the 2 litre lump is quite, i walked past the mondeo when i got it and didnt even know it was runny
mind you, the 2 litre lump is quite, i walked past the mondeo when i got it and didnt even know it was runny
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Re: run around / project, mk2 xr2 updated 16/10/09
good stuff
i was gutted it made my exhaust quieter i only have 1 box in it

i was gutted it made my exhaust quieter i only have 1 box in it

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- jayrs
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Re: run around / project, mk2 xr2 updated 16/10/09
i hope my exhaust is quieter with the 2l in the whole estate hate my xr2i when it was cvh turbo`ed and i had 2 boxes at the back and the mid one removed
so how far you got today Jay?
so how far you got today Jay?
- dangerousdave
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Re: run around / project, mk2 xr2 updated 16/10/09
its cold were i am so must be freezing on the iow 
hes probs got the nipper doing everything whilst he stays warm

hes probs got the nipper doing everything whilst he stays warm

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- FRSJON
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Re: run around / project, mk2 xr2 updated 16/10/09
FRSJON :all looking good jay...i have pics up too....
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seen them mate, damn!
im not fussed if its quite tbh, i just hope it doesnt lose the classic xr2 sound, those that have had them will know what i mean
today not a great deal was done, it was a token day for my nipper tbh, he didnt get a chance to do that much yesterday due to heavy items etc and i didnt want him hurt, so today we done what ever he wanted to do, apart from me digging out the 2 litre from the back of the pile in the workshop, and belive me it took a while to get it out and seperate the old engine and box and put the old engine in a safe place.
had it been down to me i would of had the back in the air and stripped the back end but as i say, it was nippers day so we done what he wanted.



took body kit arches off, drivers side

inside looks to be rust free, will look better when wing off though


passanger side, when dash was out could see weld burns inside hinting at some point it had a new wing..... yeah im sure..



oh dear
still, inside also looked to be fairly rust free, there is a little area i wanna look at more close when wing is off but its solid so might just be flakey sealent or something



nipper wanted dash out so...

out it came
i wanted to get the screen out to see what sort of rust was hiding under the rubber on the scuttle
oh dear i have to break the grinder out for 10 seconds



so there ya have it, not a great deal of progress but i got done what i wanted to get done on it this weekend and nipper had fun helpping and will be helpping again next week
- jayrs
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- FRSJON
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Re: run around / project, mk2 xr2 updated 16/10/09
mate both rear arches are shot inner and outer, i can tell you that much, but the floor looked to be sound if that helps
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- jonboisescort
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Re: run around / project, mk2 xr2 updated 16/10/09
im in deep shock. lol
but i know sooner or later when time allowed i knew you would crack the whip on this one. Not too much rust tbh. Now i know why you needed them panels
keep it coming dude


~nomad~ :Good god I love Clark.
- knuckles
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Re: run around / project, mk2 xr2 updated 16/10/09
At least the scuttle panel is ok mate
I'm sure you'll get it looking sweet mate, plenty of welding practice for you
You keeping the standard look on the outside when finished ?

I'm sure you'll get it looking sweet mate, plenty of welding practice for you
You keeping the standard look on the outside when finished ?

- Turboboy67
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Re: run around / project, mk2 xr2 updated 16/10/09
Looking good mate, its pretty rust free for its age! 

- Dave G fsi
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Re: run around / project, mk2 xr2 updated 16/10/09
Dave G fsi :Looking good mate, its pretty rust free for its age!
hold your horses.... you aint seen the rear stripped down yet mate


~nomad~ :Good god I love Clark.
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Re: run around / project, mk2 xr2 updated 16/10/09
Your a bad influence to the little nipper Jay! Making him do all the work while you stand back and have a fag...
Give it 30 years, and i bet he will be going the same lol. Nah im joking. Progress looked good. Front looks fairly rust free, but im sure the back will make up for it
Lets hope not though! 
- - Danny Boy -
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Re: run around / project, mk2 xr2 updated 16/10/09
nice up date
scuttle pannel looks good

keep up the good work, glad the apprentice had fun

scuttle pannel looks good
not happy!!...hope you find more rust soon....
keep up the good work, glad the apprentice had fun


- rsonblackwheels
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Re: run around / project, mk2 xr2 updated 16/10/09
cheers guys.
the boot fllor has been welded as have a couple patches on the inner wings, but my old man done that when i first got the car, and tbh i dont think its gunna budge, when he welds, he fcuking welds! lol, hench why i let him do the welding, hes better at it than me.
as for the rear, its solid............ soild news paper and grip fill on the arch lips
yes yes i bunged it in there to get it through a mot and it passed too
, but there wont be any grip fill when im done, just pure non ruty steel!
those that have read along know what panels i have already and what ones im getting, and the welding that has been done so far may well be cut out and done again as it was patched on for the mot, good enough for years to come, but seeing as the cars coming to bits, why not do it 100% right eh.
shaun, yes and no mate, i have a couple plans which might work they might not, but over all yeah its gunna look standard, well apart from the wheels of corse
the dash might be staying too now, dunno if i can reallty be ar$ed of going down the mk3/mk4 route dash wise, but should anyone come across a black dash for a mk2, i wanna know! im sure ive seen a mk2 with black dash donkies ago but i cant honestly remember
the boot fllor has been welded as have a couple patches on the inner wings, but my old man done that when i first got the car, and tbh i dont think its gunna budge, when he welds, he fcuking welds! lol, hench why i let him do the welding, hes better at it than me.
as for the rear, its solid............ soild news paper and grip fill on the arch lips
those that have read along know what panels i have already and what ones im getting, and the welding that has been done so far may well be cut out and done again as it was patched on for the mot, good enough for years to come, but seeing as the cars coming to bits, why not do it 100% right eh.
shaun, yes and no mate, i have a couple plans which might work they might not, but over all yeah its gunna look standard, well apart from the wheels of corse
the dash might be staying too now, dunno if i can reallty be ar$ed of going down the mk3/mk4 route dash wise, but should anyone come across a black dash for a mk2, i wanna know! im sure ive seen a mk2 with black dash donkies ago but i cant honestly remember
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Re: run around / project, mk2 xr2 updated 24/10/09
wel bit of a update so far, nothing major as been messing about putting another light up, getting the back end up and hit a few problems today but nothing i didnt over come
first up got the back end up, forgot about the lack of jacking points on the mk2 so was a bit of a pain to get it jacked up with the jack out the way of where i wanted to put the axle stands but got it done in the end
rest of the kit came off to see what was hiding behind it, but i knew about the rear arches anyway, and the sills are in better shape than i thought, about 8 inchs from the rear arch in is shot on passanger side and about 5 inch on the drivers side, so might just repair them by cutting the rust out rather than fit a complete sill, but ill see how i feel at a later date
boot floor on the passanger side was rotton when i got it and it was patched for the mot, but as your see from the pic's, its pretty bad looking, but not as bad as it looks and should be a fairly easy repair once its all cut out, but as ive said before, when my dad welds, he fcuking welds! so that temp plate is proper on there!


passanger arch, bear in mind it was welded and bodged for mot when i first got the car


passanger sside, again welded some bits in and filled the rest, not as bad as the passanger side but still shot tbh, both passanger and drivers inner wing lips need doing too

boot floot passanger side, common prob with the mk2 thanks to the washer bottle being in that corner and ford putting sponge in the cavity and behind the bottle, nice one fords, great thinking again.... not every muppet can fill the bottle without spilling water
not the best pics, but the boot was plated on the inside so doesnt show the hole fully tbh


under side shot, to be fair, it looks worse than it is, its all surface rust and a wire wheel on a grinder would remove it all

random shot

this stopped play today, and the fact it was 6pm:lol:

problems i had today wern't anything major, trailing arm bolts undone fine, fuel tank bolts fine, even the rear ARB clampos and brackets came off, but the rear solid brake lines
no matter how hard i tried they would not undo, then the spanner slipped and a pipe twisted and fractured
right where it was a bit rusty in a clip
, out came the cutters and i cut the fcuker off, when i tried the other side that was tight as $hit too, so just cut that fcuker off too.
no biggy though, both solid lines go from the flexy lines into the bias valves which is on the under side at the back, so i can and will make new lines up for them, might even just make complete new lines front to back yet.
oh and something i love about the xr2, when its below the red it keeps going, and why, cos the tank still has a gallon and half of fuel in it
i took some bits over for the car too, no pic's though, and there bits i found in the shed, like a complete set of brand new black dimond braided brake lines, ok for a mk3 but will fit the mk2 also, new bushed, rear shoes etc, like a aladdins cave my shed
, but i do have 2 brand new rear brake cylinders somewhere for the mk2, im damn sure of it but you think i can find them!
anyhow thats it for today.
first up got the back end up, forgot about the lack of jacking points on the mk2 so was a bit of a pain to get it jacked up with the jack out the way of where i wanted to put the axle stands but got it done in the end
rest of the kit came off to see what was hiding behind it, but i knew about the rear arches anyway, and the sills are in better shape than i thought, about 8 inchs from the rear arch in is shot on passanger side and about 5 inch on the drivers side, so might just repair them by cutting the rust out rather than fit a complete sill, but ill see how i feel at a later date
boot floor on the passanger side was rotton when i got it and it was patched for the mot, but as your see from the pic's, its pretty bad looking, but not as bad as it looks and should be a fairly easy repair once its all cut out, but as ive said before, when my dad welds, he fcuking welds! so that temp plate is proper on there!


passanger arch, bear in mind it was welded and bodged for mot when i first got the car


passanger sside, again welded some bits in and filled the rest, not as bad as the passanger side but still shot tbh, both passanger and drivers inner wing lips need doing too

boot floot passanger side, common prob with the mk2 thanks to the washer bottle being in that corner and ford putting sponge in the cavity and behind the bottle, nice one fords, great thinking again.... not every muppet can fill the bottle without spilling water
not the best pics, but the boot was plated on the inside so doesnt show the hole fully tbh


under side shot, to be fair, it looks worse than it is, its all surface rust and a wire wheel on a grinder would remove it all

random shot

this stopped play today, and the fact it was 6pm:lol:

problems i had today wern't anything major, trailing arm bolts undone fine, fuel tank bolts fine, even the rear ARB clampos and brackets came off, but the rear solid brake lines
no biggy though, both solid lines go from the flexy lines into the bias valves which is on the under side at the back, so i can and will make new lines up for them, might even just make complete new lines front to back yet.
oh and something i love about the xr2, when its below the red it keeps going, and why, cos the tank still has a gallon and half of fuel in it
i took some bits over for the car too, no pic's though, and there bits i found in the shed, like a complete set of brand new black dimond braided brake lines, ok for a mk3 but will fit the mk2 also, new bushed, rear shoes etc, like a aladdins cave my shed
anyhow thats it for today.
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Re: run around / project, mk2 xr2 updated 24/10/09
good progress mate
not alot of welding to do by the looks of it

not alot of welding to do by the looks of it

- jonboisescort
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Re: run around / project, mk2 xr2 updated 24/10/09
cheers dude.
not a great deal tbh, although im sure i will end up cutting bits out im not happy with and re-doing them
might crack on with the bonnet tomorrow, getting it all sorted for opening the right way, but i am tempted to start cutting bits off
oh, btw for anyopne interested, im hoping to have this car at ford fair 2010 along with my rs, who wants to place bets on it being there or not
not a great deal tbh, although im sure i will end up cutting bits out im not happy with and re-doing them
might crack on with the bonnet tomorrow, getting it all sorted for opening the right way, but i am tempted to start cutting bits off
oh, btw for anyopne interested, im hoping to have this car at ford fair 2010 along with my rs, who wants to place bets on it being there or not
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Re: run around / project, mk2 xr2 updated 24/10/09
Oh no Jay!!!! not again u remember what happened last time!!!


- niracka
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Re: run around / project, mk2 xr2 updated 24/10/09
remember though, when i first stasrted on the rs it was outside on parents drive and it was weather dependant as to what got done and when, this time the xr is in the garage, warm (ish) plenty of light, power, all tools about, and i dont have to waste a hour getting all the tools out, then a hour putting everything away at the end of the day, so fingers crossed it should take so long this time round.
got a up date coming, just up loading some pics
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Re: run around / project, mk2 xr2 updated 24/10/09
more fags required for next week, and a case of stella.......
anyway it doesnt look too bad for something thats only a year younger than me
so finished christmas mate????
so finished christmas mate????
- dangerousdave
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Re: run around / project, mk2 xr2 updated 25/10/09
small update today, finished stripping the bay, got all the lines etc out from the under side, bias valve proved a fcuker thanks to a rusted nut and the stud spinning, but as luck would have it-ish, the bracket was rusted and broke off fairly easy.
poked a hole in the boot floor on the side i thought was fairly sound
, and gen done a few odds and sods, but was looking into the bonnet mounting mainly, i was on my own and tbh didnt get very far with that, but i worked out a few problems i thought i was gunna have and think ive sused the catch problem, so hopfully next weekend the bonnet can be rigged up on the hinges and a catch can be fitted to make it all work, thanks to jon going to remove a couple bits from the fiesta hes breaking, cheers mate
, once this is done i have the lines on the bonnet to work from and the wings and front panel can come off, but i will be raising the car higher and making the jig for it so the body is fully supported and will not twist or bend.
thats the plan for next weekend anyway, after that i wont be able to touch the car "really" for a couple weeks due to doing 2 weekends on standby in a row, but over all the work is going to or better than planned, as i planned really to have it stripped, and mounted on a home made jig ready for panels to come off for over christmas, and sdo far, so good
anyhow, i know everyone likes pics so heres some

these are just sat there, but you get the idea


popped the old battery try off, new one.... well as ive always said about pattern parts, the fit is $hit!
the wing repair part is coming off as its not needed, and im thinking ill make the tray bolt on rather than weld on, that way it can be fully protected under it and cleaned when ever i want



thought it was surface rust till my finger vanished before my eyes

i had a xr2 for breaking years back, and when i took the rear windows out i was shocked to see just howe much of the lips just plan wasnt there
fearing the worst, i removed the rear windows to see what fight i had
passanger side, no rust!

drivers side

little bit, but lets face it, it aint hard to sort that out!
grind, and braze over (as braze wont rust ) and job done

thats it, as i say didnt get a great deal done today but did have problems, and a accident when a shed load of metal fell off the metal storage boxes right next to my foot, lucky, had it hit it, it would of smashed my foot right up
roger, over and out
poked a hole in the boot floor on the side i thought was fairly sound
thats the plan for next weekend anyway, after that i wont be able to touch the car "really" for a couple weeks due to doing 2 weekends on standby in a row, but over all the work is going to or better than planned, as i planned really to have it stripped, and mounted on a home made jig ready for panels to come off for over christmas, and sdo far, so good
anyhow, i know everyone likes pics so heres some

these are just sat there, but you get the idea


popped the old battery try off, new one.... well as ive always said about pattern parts, the fit is $hit!
the wing repair part is coming off as its not needed, and im thinking ill make the tray bolt on rather than weld on, that way it can be fully protected under it and cleaned when ever i want



thought it was surface rust till my finger vanished before my eyes

i had a xr2 for breaking years back, and when i took the rear windows out i was shocked to see just howe much of the lips just plan wasnt there
fearing the worst, i removed the rear windows to see what fight i had
passanger side, no rust!

drivers side

little bit, but lets face it, it aint hard to sort that out!
grind, and braze over (as braze wont rust ) and job done

thats it, as i say didnt get a great deal done today but did have problems, and a accident when a shed load of metal fell off the metal storage boxes right next to my foot, lucky, had it hit it, it would of smashed my foot right up
roger, over and out
- jayrs
- Elite Post Master


- Posts: 31520
- Joined: Mon Apr 19, 2004 10:32 pm
- Location: I.O.W
- Your car: FRST, XR2, ST170, ST225
Car: 1991 Ford Fiesta RS Turbo
Re: run around / project, mk2 xr2 updated 24/10/09
dangerousdave :more fags required for next week, and a case of stella.......![]()
anyway it doesnt look too bad for something thats only a year younger than me
![]()
so finished christmas mate????
defo more fags, i ran out today, prob why not much got done
finished for christmas, yeah right
- jayrs
- Elite Post Master


- Posts: 31520
- Joined: Mon Apr 19, 2004 10:32 pm
- Location: I.O.W
- Your car: FRST, XR2, ST170, ST225
Car: 1991 Ford Fiesta RS Turbo




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