Ford Escort MK1 Zetec water rail DIY. Car Restoration. 

You could leave the thinner strips of box connected and tap them around to create the radius.

You could use a ball bearing placed over the hole and hammer it (to "find" those holes).

bi meatal hole saws are good, various sizes are available and are quite reasonably priced coz not every one can afford a spanky plasma cutter, neat looking job, though may have been better with stainless steel.

I do like the way you say "Just £20 in materials" the skills to do the same and make it look good, priceless. Many might try, only a few will manage.

Brilliant simplicity! Well done and thanks for filming it.

Some great old Skool fabrication ! Well done 👍🏴󠁧󠁢󠁳󠁣󠁴󠁿

Champion 👍

Evening Dave. Garage engineering at its best 🤩 Fabulous fabrication 👍🏻

A good quality automatic centre punch is a god send for things like that.

Great Job Dave, actually thinking of putting a Zetec into my TD (Mk3) Cortina. It would be easier for me to use a 6 cylinder engine from a Falcon here in Australia, the only issue is those engines are heavy. I have had a 6 cylinder engine in a TE (Mk4) cortina and they are front heavy.

Transfer punches are what you need

A ball bearing is good for marking centre, a bit awkward on the vertical mind.

Fantastic fabrication Dave looks better then the items available tbh 💪🏻

brilliant video very clear and nice to see gloves used on your hands for protection before welding. Not like those american shows where they shut there eyes for eye protection

Hats off to you Dave brilliant job👍👍

Great stuff Dave, thanks and keep the awesome videos coming.

Thanks for doing this Dave, a man who keeps his promises. Excellent work...

Hi,when using the fiesta thermostat housing,where does the small outlet at the top of it connect to? Thanks

Thank you for posting this Dave I was looking for a way to make a water rail for my zetec into my 100e and this is absolutely genius Your fabrication skills and old school engineering is what I love about our job and hobby I am going to copy this as it is as good or better than any alternatives out there and as you say the material cost is negligible I will send you a pic when it's made Thank you again for sharing this Cheers bud

Look up 'Optical Centre Punch' Dave. Not too hard to fabricate your own either.

Great video congratulations on 1000 viewers

Genius… amazing work and made out of nothing really …nice one Dave super job 👍

Congratulations on getting to 1000 viewers Dave, your videos are excellent.

Nice work.

I put some grease on the part that I’m copying and then push the steel against it

Nice piece of engineering Dave it looks brilliant

That is awesome! I think my mig welder is under utilised, you seem to make good use of your plasma cutter too!

Looks great 👍🏻👍🏻

great video again dave

Great video but how did you fit a thermostat ??

That looks Fab Bro👍 I can see why you chose to make one considering how much they cost. I had similar troubles fitting the Toyota MR2 lump in my Anglebox so i know what you're going through. If you bought one then where's the fun in that! You have done some nice welds too.

Nice engineering mate

What other mods do u need to do to make a zetec fit ? Will u be doing videos for them too ?

Hi we have a 2L Zetec black top with ECU and wiring loom do you know what wiring we need to keep it fuel injection please and love your water rail this weeks job is to make one thank you for that £200+ saving

After my son finding you on RU-vid, it was dad dad there’s a guy on RU-vid who’s got the same uniform as you lol, Dave I’ve really enjoyed watching your videos I’ve caught up with them all now, keep up the good work mate ps are you an x or do you work for the co still !?

Hope it doesn't leak

Are you going to put a rebate in for the thermostat