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Usually, finding a suitable Mk 1 Escort shell means making sure there is as little rust as possible in the main structure, but at Whitspeed this is not the main criteria.  All we are looking for is good upper structure, i.e. roof, door, boot and window frames, the rest is less important, just a bonus really.  As such, the number of available shells for a chassis car is slightly higher than for ‘normal’ restoration, and also cheaper.  Once we have stripped our car of all mechanical components, we cut away what we know we no longer need.

We then make the basic chassis to suit the dimensions of the body shell and the major components of the project.  Most dimensions are dictated by the wheelbase of the original car, the engine and gearbox, the axle, the wheels and tyres, etc.  Basically we think of the chassis as a large bracket to attach things to each other.  All this must be done on a flat surface which is why it is on our special chassis jig.  The main structure soon comes together so the body can be fitted.  We are often asked if we work to detailed drawings, and the answer is simply NO.  Experience and knowledge are our tools.

Major components like axles, suspension, brakes, engine and gearbox can all be added now and soon the whole thing starts to look like a car again.  This is the time when all the major fabrication takes place and is the most interesting.  We always try to make each bracket do at least two jobs, and it must also look nice.  Form as well as function.  Often we have to make temporary brackets to hold one item in position, then when we have more items in situ, we then remake the bracket to its final form.   We want the cars to look very simple and uncluttered as well as still having full functionality.  We are always planning ahead during any build, just more so with a full chassis build.

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