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  1. 67 points
    OK so I was thinking I was not far from painting the shell when I realised my repairs to the rear guard behind the drivers door had a slight bulge, maybe 5mm outwards in relation to the edge of the door shuts. A classic case of working up close and not standing back to look at the complete picture. It showed up worse when I sat the door in place. I thought I had taken a photo but alas no- trust me when I say it would have done my head in noting it each time I looked down the flank. This panel had been badly bashed in at some point we had popped it out. But obviously too far sadly I never realised until now. I tried beating it back in but no luck. It had been previously repaired by someone else and was full of lots of sharp dents. So this happened... Following that I did a super careful replacement of the steel, butt welded in, with very slow careful welding so not to warp anything. In pictures... It turned out great. I still needed a skim of filler to get it spot on but considering what it was like prior I'm happy with it now. It lines up really well with the door... I then gave this and most of the rest of the shell another coat in primer, smoothed it all back with 400. Oh yawn. Helps having beer and loud Reggae playing. Hannah just loved sanding... With the sanding done I then preceded to turn the workshop into something resembling a Smurf murder house. If there was a song to be played afterwards it would have been this... https://www.youtube.com/watch?v=68ugkg9RePc We masked it all up and I painted the door jams, door backs, engine bay, interior, frunk, door bins etc. Next day, re- masked the shell and painted the rest. On the first days painting it was so hot at 34 degrees... The following day time I started as early as I could but it was still about 28. Luckily a very dry heat. Not fun in all the gear... I never really considered how far the blue mist would travel. It covered everything. Great fun. Now we have a blue floor which luckily is slowly going to wear off I think. I hope. After it was finished I shut the doors and let it bake in the oven that was the shed, drank a cold beer and went to the beach for a long swim. Here is a blue Imp. Its very similar to an original Imp colour I like so I went with this. Not sure of the name of the colour. Its very bright and changes from a mint blue to a aqua blue in different light. I'm so relieved to have finished the painting. It'll need a flat back to get rid of the orange peel and shine so it looks more like a original paint job. But I'm going to ignore that job until after the car is road legal. Enough body work and painting!!!! Its time to bring the other Imps inside and play musical chairs with all the various parts. Pick the nicest bits and reassemble one car from them all... It certainly is a fair bit better then when we first looked at this shell a year ago and I'm pretty stoked to be at this point in the restoration
  2. 66 points
    Need to do updates more often so they're smaller! Put the tray on as I needed to see where I could run the fuel and brake lines. Also borrowed a pair of wheels off one of my parent's cars, to test the tire sizing. Bought a fuel filter and made a stainless steel bracket to hold it. Made some mounts for the rear bumper to bed brackets, as they were welded on before. Got out the LED tail lights that I've had for ages and made up some stainless brackets and polished them. Started running the brake line out of copper-nickel tube. Also got some 5/16" lines for the fuel lines. Made some stainless clamps to hold them all together and to the firewall and chassis. Made some bits for the column change linkage. Top middle piece mounts on the firewall around the column and has some little stoppers that make it so the gear stick needs to be pulled out to change from certain gears. Left bit is what goes over the stoppers and pivots with the gear stick to push the rod bit down, which then pushes the right piece down and change gear. Thought at first it would have to be some super complex system with cables and stuff but this way was actually pretty simple to make work. Then I needed to make up a indicator on the column to show which gear it was in. Drew on up in Solidworks and laser cut it out. The accelerator cable needed some modifying to work, it's wasn't quite long enough to reach the pedal, so made a new bracket that moved the housing closer to the throttle, which allowed for more cable out the pedal end. Then all it needed was a plate with a lot in it that bolted to the pedal to hold the little ball on the end. Have had some big train air horns for ages. Couldn't find anyway with enough space to fit them, as they were originally mounted together in a triangle shape. So pulled them apart, made some new brackets and bolted them up under the cab to the chassis. Need to just run some lines to them. Some boxes of stuff finally arrived from America. They included some front windscreen stainless trim, door panels and the surrounding trim. Might replace the door panels one day as they weren't as good as I thought they'd be for the "deluxe" spec ones. Also arrived were some wheels. 15x8 Artillery steel wheels with baby moons and beauty rings. Spent ages trying to figure out what colour to paint them, didn't really want to go red (what everyone does) or black (spent too much money on them for them to be hidden). Decided a bronze colour would look good and hopefully not too out of place. Then spent more time trying to find a nice bronze.
  3. 64 points
    All the bits are clearcoated. Came up alright, got way too many runs on the cab, but that's okay as I'll be re-coating it all again once it's assembled with some flatter clear. At least it's all sealed up now. Installed some black fender welt between the bed and the guards. Started installing some of the parts. Put the door latches in, had to replace one of the springs behind the interior handle on the left side as it had snapped. Squeezed some Dynamat on to the outer skin of the doors and wooow what a difference that made to the whole door including the inner skin. Couldn't wait to see what the gauges looked like, so in they went. Got the door windows and quarter windows in, what a frustrating time that was, since they had to be installed in the right order and it all has to be fitted through the small slot in the top. Put an LED in the original interior light housing, wired it up and fitted. Puts out some decent light. Pulled apart the old headlight surrounds and put in new spring and seals. Gave them a bit of a polish up as well. Bought some new sealed beams, no-one could seem to find any semi-sealed ones with the domed glass when I was looking. Found some in America after I bought these though, but will try these out for now and if they're rubbish change them later. Fitted one of the inner guards when the engine was in and realised that trying to make headers was waaaay too much effort, time consuming and there really just is no space in there, plus the factory ones already fitted perfectly. So cut off the ugly heat shields on the factory headers, tidied up some of the welding, ground out the lumpy weld on the inside of the flange, painted them with high-temp paint and then wrapped them in heat-wrap, look much better. Would of really liked to build my own headers, maybe on the next project, as I have 20x 1-5/8" U-bends arriving from America next week haha. Put the cab on so I can see where the brake and fuel lines can run. Looks like it could actually be finished sometime soon haha.
  4. 63 points
    Introducing the newest member to the rotary international auckland, in the form of a super project Mazda Rx2 Coupe straight outta somewhere near Compton but might take a while in the LA traffic. Back in February there was slight intoxication involved when this little red coupe showed up on a Facebook group, and thought 'yes this could be a nice daily'. Not overly reasonable considering it was in LA, and there was no garage space available, but no amount of sense-talking could stop the purchase and after being told our Mexican mate would sell it to another guy for double, I taught him a lesson by sending him money, chucked Stephen's RX7 out in the rain, and arranged shipment. Supposedly from the Arizona desert (yet with several crowbar dents around main entrance points) it has survived hot sun, a brick through the windscreen, and a seemingly nasty break up thanks to Jessica being a tramp and a too-timer: As far as we know it’s a 1973 RX2 S1/S2, with a poorly pulled apart factory 12a twin dizzy which fascinatingly was resting on the crossmember as an engine bracket, surviving a bumpy boat ride and several tow trucks. The list of what it has is far shorter than what it needs as it included the seats, engine and auto gearbox, couple of bits of chrome, old mates dad's truck rear view mirror, half of the Arizona desert in the doors, and a creepy Christmas doll decoration. Sorted: Thankfully don't have to invest in a paint job, as Jessica's ex has done the custom airbrushing. Got an extra windscreen as sadly the brick shattered the one in it. Plans: Not sure of engine yet as deciding between keeping original or moving to a 13B. Received an upholstery quote so that will be instead be mostly done by Rotorhoe's hobby shop. Widened steels, slam as per rules, get on road with guidance of supertrapp and jillyz music (cost effective as no radio required) Your kind thoughts and sympathy are appreciated
  5. 58 points
    So the engine bay thing kind of took off. Some egging on by a certain lanky Auckland member... Motor out. 20181216_135918 by Richard Opie, on Flickr You can see, there's multiple useless holes in the firewall. These include, but are not restricted to the original heater inlet/outlet, brake booster, loom, aircon and all the other weird shit that I don't need anymore. Same goes for the brackets on the firewall. So what next? KP61 Phone-1 by Richard Opie, on Flickr Trekked down to see @oftensideways with the KP in tow. For those of you who don't know Sean, he's a freakin wizard, and a top bloke to boot. Someone I am privileged to consider among my mates. He'd agreed to weld up the engine bay for me, and with Bex being away visiting her family over the break it was a great excuse for me to get out of the house and go for a bit of a drive. KP61 Phone-2 by Richard Opie, on Flickr I didn't really get many shots in progress, but here's what the firewall looked like when it was time to load up and hit the road (the next day, even!). All of the large holes have been filled with steel patches. MIG'd in place then TIG welded to finish. The little stuff with captive nuts on the other side have been filled by MIG welding. Then a bunch of hammer and dolly work to get the shape back. And so we took off home. Straight into @sheepers shed... as I said, this all happened a bit quicker than I am used to. KP61 Phone-3 by Richard Opie, on Flickr Front off, subframe and suspension out. Then onto the labourious job of prepping for paint. KP61 Phone-4 by Richard Opie, on Flickr This is after the initial prep work for a coat of high build primer. You'll note the brake line holes and etc in the inner guards have also been filled. Thought it was a good idea while I was down at Seans to do it once and properly. This first prep really started to reveal just how good the job Sean did was. High spots at an absolute minimum - which is great, as these are way harder to fix than low spots, for obvious reasons. KP61 Phone-5 by Richard Opie, on Flickr Sheepers sprayed the first coat of primer on the bay that same night. Was a fairly long day, but super cool nonetheless to see an inkling of what the final product was going to be like while the primer was still wet. Promising. Of course, lots, and lots, and lots of sanding still to come... KP61 Phone-6 by Richard Opie, on Flickr This is after a wet sand. A whole days worth of wet sanding. You can see all the red spot filler on the firewall. This is ALL WE NEEDED TO FILL IN. Let that sink in for a while. After the amount of welding heat and bashing that had gone into the firewall, the requirement to crack out the bog was slim to nil in the end. That's how damn good Sean is. Regardless of how good it was, I ended up with trench-hands from being in wet gloves all day, which was equal parts gross and hilarious. But then the second coat of primer went on... KP61 Phone-7 by Richard Opie, on Flickr HOW GOOD. The followup to this was pretty much a rinse and repeat of the earlier scenario. But with more hand sanding, and less power assistance. Definitely a learning process, figuring out how best to make the paper do the work, while maintaining a smooth surface ready for the base coat. KP61 Phone-8 by Richard Opie, on Flickr This was about the moment I began to properly fizz. Couldn't stay in the shed while it was being sprayed as I didn't have appropriate respiratory protection, but when the door rolled up... this shot of the bay coated in a colour matched red was the result. Not bad? Major tent pants moment was still to come, however. KP61 Phone-9 by Richard Opie, on Flickr Look at that! You could bloody go swimming in that gloss. Sheeper was a little bit apprehensive to try the clearcoat I bought (that was recommended by the joker at CarColors Albany) since different product can apparently yield very different results if you're not familiar with spraying it. But how good is the result, testament to the multi-talents of the lanky fella on the gun. A couple of runs for sure, and a little bit of dirt got in the paint - expected for spraying it in a garage. But nothing that can't be very easily fixed. Today was a day off working on it - from go to whoa this took 5 days in total. I'm heading back tomorrow to touch up the underseal in the guards and also reassemble the car, take it back to the shed it lives in and crack on with the engine while I let the paint harden enough to wet sand or cut/polish the imperfections out. Thanks for looking.
  6. 57 points
    Havnt updated for a while. Been in the US living up the Freedoms. Ive been working on a lot of CAD over the last 1-2years and have just recently bought a massive 3D printer to make casting patterns. The plan is to stock pile patterns and then hit it hard when Im back in NZ Currently doing patterns for the crankcase. I'll update more on Instagram. @Barlow.Jobs
  7. 55 points
    Learnt a lot in the past month and a bit. Main thing being that you should probably lube your fuel injector o-rings when you go to put them back in. Got the engine running, was only running on half the cylinders. Discovered there was no fuel going to the rear half cylinders, so decided to pull out the injectors. Took them into town and put them on an injector tester and nothing happened. Was told they can gunk up after sitting for awhile. So went off back home and gave them a spray with some cleaner and smashed them on the ground until they started clicking freely again with power to them. Got them all sounding really good, so in they went (without any lube, thinking back it should of been something that should of come to mind, but I guess I was just in a rush to get it running!), as they went in they must of torn the o-rings. I got the intake and everything back on and together and we started it up again. Ran mint!! So turned it off to see how it would start again, flat battery. Chucked the charger on, and then decided we'd put the wheels on, piece it a bit more together and go for a drive up the driveway. By time we got it together and off the hoist, a few hours had past and so had a decent amount of fuel past the o-rings and into cylinder no.5. Cranked it over and it didn't want to start very easily, so gave it a few more attempts and finally started up with a lovely knocking noise! We thought maybe it was just something loose in the bellhousing, as when we first started it we quickly realised there were no bolts in the flex plate to the torque converter. Anyway drove it up and down the driveway and then back on to the hoist. Decided over Christmas we'd pull out the transmission to have a look in there, other than the weights on the flex plate being ripped off by the torque converter there was nothing that obvious. Started the engine without the trans in and it still had the knock, which was a disappointment. Our neighbours Tony and Jason, who are a bit more mechanically minded came over on Boxing day after hearing that it wasn't transmission related, and went over everything they could think of. Eventually after a good few hours we narrowed it down and decided to check how high each piston is coming up by sticking a threaded rod with a nut on it and turning the engine over by hand. Got around to cylinder no.5 and it was about 5-6mm lower than the rest. Was obvious at this stage that we had a bent rod that was caused by hydraulicing the engine with fuel. Out came the engine, onto a stand, flipped over and then pulled the sump off. It was pretty bent! The crank smashed up the bottom of the piston, but other than the rod and piston everything else looked good. The engine is now at the rebuilders and injectors have been professionally cleaned with new o-rings. The buggered o-rings on the injectors. Since I had awhile off work over Christmas and the engine debacle halted progress a bit, we decided it was a good time to sand out all the runs in the clearcoat and give it another couple of coats with some flatter clear since I wasn't quite happy with the last stuff I used. Used some PPG autothane clear with flattening base in it this time. Was way easier to spray, looks waaaaay better, a lot smoother and a more consistent flatness. Also the extra coats covered the rust up a bit more, as before it didn't seem to be covered well in the rusty areas. With the engine out it was a good time to go through and tidy up a few things. Made up some stainless heatshields that cover the wiring on one side and the fuel and brake lines on the other. Also wrapped some of the exhaust in heat wrap to try and help keep some heat away. Ignore the plastic cable ties, the ones that came with the wrap were too short, and I'll change them soon. After trying to drain the coolant I decided it'd much easier if there was a drain plug, rather than having to disconnect a hose and having it run straight onto a crossmember. Next thing to do was sort out the fuel filler. Turned out the u-bends I bought for the headers were the correct size I needed, so took one of them, cut it to fit and welded a breather pipe on the side. Made a stainless pipe that goes from the 1 5/8" u-bend to 2" on the tank. Also added some gas struts to the rear bed lift up part. Whilst under the rear end noticed the rear airbags were only mounted on the bottom with bolts and no washers. This was mostly because the mount was so close to the diff tube and the airbag mounting holes had quite a small PCD, you couldn't fit much else in there. Came up with these plates that mount to the airbags with a countersunk screw and then have the studs stick through the outer of the slotted hole in the diff mount. Heaps of room to get a nyloc nut and washer now. Was running out of stuff that I could think of to do, so my Dad made a start planing and fitting the Matai wood planks that I bought quite a while ago. Fitted in they looked a bit weird being natural, too bright or something. Had some Japanese stain lying around that we tried and I quite liked it. So went and wiped that all over it once it was fitting well. Then wiped over some Scandinavian oil and came it out really nice. Got the windows installed, he still needs to come back and finish them off. The front window stainless trim doesn't fit as well as I'd hope it would, sorta sticks out a bit, but we're sure it's in there properly. Probably a combination of the crappy re-pro rubber and trim not being 100% right to start with, as I've heard of a heap of people having troubles with windscreen rubbers not fitting nicely on these. Supposed to be taking this to Nats in less than 6 weeks hahaha
  8. 48 points
    All patterns completed for the crankcase! Just finishing the runner system now. Then onto the sump
  9. 42 points
    I said I should post more often so they're smaller, but here we are, another big post. I didn't think I had much to post because the majority of it has been wiring and that's boring, so not many photos. Air horns are now fully plumbed up. Used one of my dads cast aluminium fuel logs and used it as the manifold which has the main inlet and then each individual line to each horn. Bought the biggest battery that would fit inside the box I made earlier. Then drew up a clamp for it, laser cut it from some ali and folded it up. Getting better at ali welding! Fitted back into the under floor hole. Bought some battery cables and hooked them up to the main engine power junction. Wanted a killswitch mounted somewhere, made up a bracket for it out of stainless steel. Decided under the seat was the best place that is still reasonably easy to access and hidden from sight. Made an aluminium glovebox since the original cardboard one had seen better days. As the dash is quite short, it would of been hard to tuck up the fuse box behind it and not have it being a eye sore. So designed the glove box to fit the fuse box inside out of sight, which also tucks the wiring up. Started with the air bag wiring as it was the easiest to do and I don't have very much experience with it, other than a couple of weeks work experience nearly 5 years ago. Once the airbags were all done and working, I made a start wiring the rest of it. Started at the rear and worked forward. Need to make a reflector of some sort for the licence plate light. Since the engine had already been rewired at some stage, it had it's own fuse box and relays ready to go. Decided to mount the fuses up under the dash, after extending the wires to reach. The relays stayed in the engine bay since they shouldn't need to be accessed as often. Had to rewire the starter relay as it had full power going through the inhibitor switch and apparently that wouldn't be good for the switch, so cut and swapped around some wires. Stole the power steering pump off of my parent's Mercury that also has a Nissan V8, since they won't be needing one for a while yet. Only just fits, the pulley is pretty close to the chassis rail and the tensioner bolt is very close to the crossmember. Got a new high pressure line made up by using the original fitting from the Nissan line and the rack end of the Jaguar line. Assembled the inner and outer fenders and then lifted them in place, to check everything still fits. The engine bay looks pretty nice (other than the ugly engine)! The accelerator cable needed a new bracket to hold it in place since the original didn't work that great anymore. Made up a V2 under dash panel for the ignition switch and other numerous switches. Looks better than the first one, it might end up black eventually I think, brushed stainless doesn't really match anything else. From left to right has the ignition, heater, fog lights, wipers and horn switch. Also charge and oil pressure lights. Made a stainless steel bracket to mount the tacho gauge under the dash. Also above it is the headlight switch. Had to make a bezel for it as the hole in the dash was 25mm and the switch was supposed to only fit in a 8mm hole. Park/indicators and headlights all wired up with some waterproof plugs. Managed to blow the 6v sealed beams in the fog lights, so got some new GE 12v ones from America. Made some stainless steel spacers for them to sit on. Need to get enough courage to drill some mounting holes in the front splash apron now. Noticed the transmission mount was broken, asked around and found Nengun.com had genuine new ones far cheaper than any where else I found. Bought some oil filter relocation sandwich plates, as the oil filter was nearly impossible to access with the inner fenders in place. Had to get a new adapter nut turned up since the supplied one was too short like they seem to be. Made a new mount for the oil filter plate since the one that came with it was pretty pathetic and weak. Then got some fittings and hose, cost way more than what I thought they would.
  10. 42 points
    yep. 2018-08-04_01-58-24 by sheepers, on Flickr 2018-08-04_01-57-08 by sheepers, on Flickr 2018-08-04_01-58-09 by sheepers, on Flickr 2018-08-04_01-58-00 by sheepers, on Flickr 2018-08-04_01-57-48 by sheepers, on Flickr 2018-08-04_01-57-36 by sheepers, on Flickr 2018-08-04_01-57-17 by sheepers, on Flickr
  11. 41 points
    Update. I hate paint prep. I could never be a car painter. Ugggghhh- so boring. Sand, fill, sand, fill, sand... luckily I have a belt sander... (Joke) Then cover the whole lot in white filler primer and spot all the bits I missed. FFS.... In between all the filling and sanding I did a few other bits. Just to take a break from sanding really but also because these jobs are ones I cant do once its painted. The engine lid (bonnet at back?) I'll be using is the fiberglass item from the race car. It fits OK and is very light plus its the much nicer looking sport item with extra vents. However it was fitted to the race car on pedestals and held down with sprung latches (I dont know the proper term for these so I just made some names up) I wanted it to fit like an original lid so I had glue some steel brackets to it. Plus it sat flat along the front edge so an extra bit of steel welded between the brackets with a curve set in would fix that issue. I welded some m6 bolts in so making captive studs. The job in photos... Brackets bolted to hinges and ready for glue.... Lid glued on and taped in place over night... It works! Yay... Now to hold it down with original style handles. I had a set of handles on one spare lid and some working latches on another. I cut things up, broke rusty bits, oiled this, wire brushed that, ground this, drilled that and other fettling until I had some working bits I could glue onto the F/glass lid. Photos of the process... Again leaving for a few hours until the glue set (which btw is Sellys 'The One' adhesive and sealer which is really good stuff for all sorts Of jobs I have found) and once I fitted the handles in place they worked a treat. Panel gaps are ok too for a F/glass lid... Part of the body prep was spraying Resene Industrial 440 epoxy primer over a few bare steel parts and the roof. I sprayed the fan assembly and radiator shroud while I was at it. Looked much better for some quick spraying and will be nice and durable... Then back to sanding. Finally I had it at a point where I could slap some primer on. It took a long time to sort the side out that had the massive cave in and dents. Its still not perfect and never will be. The bonnet too- given I had rebuilt most of the complicated front edge in steel I was not surprised that it needed a skim of filler and its still not perfect. Show car it wont be... Now this was to be the first time I have used 2 pack paint. I have previously painted cars in single pack acrylic (lacquer?) and they've come up OK but not very durable. Shane who owns the paint shop, Custom Colors, next door to where I used to work, gave me some advice and helped sort me out the right stuff for the job. This stuff is nasty and I was not going to risk breathing in vapours filled with all sorts of crap for the sake of painting an Imp. So I bought a decent full face mask and an air feed kit. I also splashed out and spent big monies on a Hvlp spray gun too! $60 at Supercheap in a sale. It'll do the job fine for the amount of work I'll be doing. I appreciate the lovelyness of all the Devilbiss and Iwata guns but not the $500 plus price tags. Also- big thanks goes out to the friendly helpful fella, Mort, at Patersons paint supplies in Nelson. So to the paint booth. Well actually to the workshop in which I had thrown some sheets over the pushbikes, strung some clothesline across the width from which hung some the doors and bonnet and shuffled things about so not to trip over whilst waddling about in my stormtrooper white coveralls making Darth Vader sounds from within my airfed mask. Its summer so I am pretty much always barefoot as is the way in NZ. However in order to not end up with primer covered tootsies I wore some old socks. I dusted everything down this morning and swept the place out, blew the car down. I opened the roller doors to an exact amount to allow just enough flow to pull the mist out (which did not work...) and preceded to very carefully and patiently clog my spray gun up. Some paint ended up on the car though. It was certainly a big lesson. This paint, a heavy primer, certainly goes off quick in the pot and at first I had not thinned it down enough. Combined with a 1.4mm tip size more suited for thinner top coats and I ended up making a mess of my bench as I frantically cleaned out the gun, tipped away one pot of paint, cursed a bit (a lot), turned the music up, and got back to spluttering my primer all over the place. I got there in the end, muttering to myself the whole time 'not to worry..its only the primer stage' and the car now looks resplendent in white. Amazing how a lovely coat of uniform colour makes something look so much neater. Also amazing how a lovely coat of primer shows up all the little pits, chips, dents, edges. Fcuk. On with the sanding. Luckily there is really only one part that I don't like which is on the horizontal swage line near the 'big dent job'. Its too flat and needs the edge building up with a bit more filler... But screw that for now. I cleaned the gun, turned the lights off and went out for a bike ride.
  12. 41 points
    I moved the shell onto the hoist and removed the last bits of rot, tiny bits around the front arch.. Work then continued on the cooling circuit. I need to get the pipes from the engine up to the front. Most people with Imps doing a front radiator conversion either run the pipes inside (too hot), under the gear change in the centre tunnel (I want to keep that easily accessible and to do it properly without having pipes below the floor line I'd still need to make some tunnels to close over) or they use the existing heater hoses (too small). The setup in the race car was like this... Fine for a race car but way too hot and in the way for a road car. I have had the intention of fabricating a separate tunnel to house the pipes ever since getting the race car. This is because if I was to run the pipes inside no matter what I try and do to insulate them there will be a fair bit of heat escaping into the cabin, plus they'll take up more room. With a tunnel the heat can instead radiate out into the airflow there should be very little transfer into the cabin. They'll take up less room and with a simple false floor above the tunnel in the front the passenger should not even know.... Plus any leaks go to the ground, the pipes can be easily attended to and the well.. it just seems a neat way to do it So I started by chopping down the removable cover (covers where the brake pedal mount would be on a l/h drive car) so I can weld it back in for a neater stiffer area. Then I marked out some lines and started cutting away... Then I cut and folded some tunnel sections up and welded them in. I have tried to keep the curves as gentle as possible without encroaching too far into the footwell. I had to make sure the pipes would be clear of the front suspension arc. Meanwhille Hannah kept busy stripping useful parts out of the racecar shell... I cut more bits out, formed more tunnel sections and ended up with a lovely clear tunnel front to back... I now need to fit the rear seat in and see how I can avoid passengers getting a hot bum. I'm not sure how close it sits to the metal base. I might just have to wrap the pipes and make some heat shields as i can box it lower due to the rear swing arm mounting point box section. I'll also add a bracing section near the front across the floor where the new pipe tunnel has potentially created a 'side impact crumple zone' or something.. Then its seat mounting time. Then paint prep!!!! That will be where things start to get very, very, very tricky! What colour? I have my mind on a on a few different light blues and even some light greens. Decisions...
  13. 41 points
    In between working on a very sweet little Chevette with a Mazda 12A I have I have been whittling away on the Imp radiator placement, fan mounting and shrouding. What started off as simple ideas turned into more complex shapes as I wanted to make it all easy to take apart for servicing, plus be super strong. Its now very beefy up front and those mount points aint gonna move a bit. The radiator mounts, fan mount and exit point and shroud have so many folded over edges that its all really nice and stiff. To start with I lobbed a hefty chunk of RHS connecting the front rails and welded to the front suspension bracket points... Then I did some CAD work and started building up a radiator support panel.. This was made so much easier by our new tool- a guillotine we bought and picked up from my Uncle when we got our new lathe from him. I will never miss making long cuts with a cutting disc and all the associated dust mask, googles, ear protectors etc. Its made in England by Pictorex, is originally for paper but good enough to do 1.2mm steel so ideal for most car work.. Once the radiator mount was made I had to sort out where the ventilation system was going to get it air from. I had cut the hole in the front large enough to allow for an extra pick up. I built a tapered box behind it and angled it take the original hose ducting, making sure it was ot going to foul either the headlight or the fan shroud later on... I went to the local radiator place for a bleed nipple and drain tap that I was going to solder in myself. He said he could fit them while I was shopping and so he did, then cleaning it and pressure testing it all for only $30. Awesome. I'll go back there once I worked out pipe placement. I had cut a hole in the support panel so I can drain the coolant out the front.. Then onto into the fan and shroud. I wanted it to flow air through well when the fan was not on so made side supports with holes and little stainless hinge bars... These were welded to the fan frame like so... Mounted in place with alloy flaps hung on those bars. I tested them by blocking the radiator intake with a well fitting piece of hardboard and firing up the fan in reverse... Works really well. Happy with that. So I started framing the outlet hole. I added a new Lada Niva tandem master cylinder in position so to make sure I would build around it to suit. The M/C was given to me by good 'ol @NickJ ( I owes ya!) and he gave me the newspaper that the box came wrapped in which had these two likely looking Russian characters on it... Framing the hole.. Then I had a point to mount the shroud to. I welded the shroud on the inside of the joins so it cleaned up nicely. I made it as swoopy/smooth flowing as possible to make the air flow out cleanly (again... most likely getting a bit carried away a bit.. but its is fun this ). It can be removed easily, two screws, without moving the tank and then the fan with its shroud can come out, two screws. Then the radiator. So to finish this lot I need to swap the top inlet position on the radiator to the other side and add a baffle on the opposite side. Given how cheap and friendly that 'Rad' fella was I'll go back there... I reckon if I touch it with my current unsuitable gas torch I'll probably end up melting all the solder away from everything! With that done I can add the channel I am planning to run the pipes under the car but out of harms way. Then I'll make some seat mounting points for the MX5 seats now spare from the Viva.
  14. 40 points
    Right, so it’s been 2 weeks since this came into my possession. Have done clutch master and slave cylinder, rear wheel cylinders, got good parts off of the other ladas, polished all the chrome (which has come up amazing! Fitted brake master off of yellow lada which was good but doesn’t seem to want to bleed up, fitted the good fuel pump from the yellow lada too so it now runs and drives under its own power! Have also polished paintwork, it’s pretty crap really but did shine up ok! Took it to the chachacha auto fiesta meet up today, bit dodgey only having handbrake but all went well! Does get pretty hot though, never went into the red but did get close. Drives really bloody well actually! Oil cap was pretty milky when I checked but hoping it was just some condensation as oil is still golden and coolant is still green. Ohyeah I also gave her the much needed slam treatment today too! Looks much better. Here it is in all its low glory.
  15. 39 points
    I’ve been lurking on this site for a while now and think I finally have something worthy of having a “build” thread. More of a resurrection than build. I figured this would be the best place Mid last year this popped up on my news feed: Naturally I hassled the bloke about it enough for him to give me the guys number. Long story short I managed to get first viewing of the car and it was only 45 mins drive from me to Te Poi where it had been sitting under a car-port for the last few years. This is how I found it: Despite the fact I was flying out on my OE a week later I still spent a chunk of my travel money bought the car (a no-brainer) and had it towed back to the old man’s a coupe days later. In a nutshell; It was running (roughly), Rego was on hold and everything was there. Last WOF was 1999. Rust has set in but nothing too major. Once I got it home I basically gave it a water blast and tucked it away into storage. I’m back in NZ now so will be getting amongst it-hoping to have it back on the road for Leadfoot 2019 but that may be a bit optimistic at this point. Cheers Jordan
  16. 39 points
    My parents came back from America and brought back a bunch of parts for me. Nothing really too exciting, just some headlight parts, steering column rebuild bits and various rubbers that I needed. The slightly exciting parts here were door arm rests and exterior door handles. There is some cool bits coming in a container soon though! They also picked up some NOS optional fog lights for a Chevy truck which are cool. The ignition switch that I got didn't work in the original bracket that fits into the dash, so tried to come up with ideas on where to put it. Came up with this, has the ignition switch and light, rpm gauge, wiper switch and oil pressure light or something. Would probably cover it in black leather to match the door cards, don't know how I feel about it though, sorta looks a bit bulky. Might revisit it later again once the inside is painted. Also needed somewhere to mount the airbag controller. Made it hinge down under the panel and pivot up when it's needed, which worked alright. Other option is to modify the original ash tray and put it in there, which I would prefer but requires more work and cutting up the dash panel. Dropped the engine back in and regretfully put the old rusty jag wheels back on to roll it off the hoist. Bought some Durapox clearcoat with flattener in it awhile ago and have tried it on quite a few different parts with varying outcomes. Unsure what's going wrong but it doesn't seem to flatten off if it's put on more than just a light dusting coat, just stays glossy if too much is put on, but it's sorta patchy/rough if it's too light. Have gotten these bits good enough, but seems like it's going to be a real pain to try and get the whole truck consistent. Had an attempt at patina-ing the grill guard. Doesn't look too bad I think, will have to see once the grill and guards are back on though. As I was having problems with the clearcoat, I did some research and turns out the suction feed gun I was using had a 1.8mm tip which is a bit big for painting/clearing, more used for primer. So we went out and purchased a new decent gravity feed spray gun. Took the rattle can primer off the firewall to put some epoxy primer on. Epoxied. High build primered, and then filled all the spot welds, little dents and welded holes that needed doing. Then spent ages sanding! Once it was smooth enough I remasked it and applied some paint with the new gun, which is quite a bit better. Isn't perfect, but good enough for a firewall. Made up some plates that bolted to the upper door hinge mount on the cab and then welded a long piece of RHS between them. Then used some tie-downs wrapped around the hoist and flipped the cab on it's back, which sits on some inner tyre tubes.
  17. 38 points
    so with some help from a cam and a dave it goes back in the hole, and all bolts up right? well sort of does bolt up. after shortening driveshaft by 95mm but its doesn't fit until you hit the things with hammers and cut and weld this and that more cad design implementations then with the winds of good luck it may be a roadworthy car again one day soon
  18. 38 points
    My Jag has finally been returned to me! The bill was very scary , because.... I ended up having to cover the funeral expenses of the mechanics who decided to try their luck in the next life. And then the rest of them went on trauma counselling / bereavement leave*, so the job took two months... I listened to the survivors tell their tale. Every nut and joint put up a fight and had to be soaked overnight, the whole rear subframe ended up coming out, and it was all because someone had apparently installed the handbrake pads upside down! This allowed the pads to move such that the backing plates were grinding away at the discs and starting to chip bits off. Jaguar changed the rear suspension for the last four years of XJS production, moving the rear discs outboard. Can't think why. After having not exactly the kindest introduction to the costs of old British luxury grand tourer ownership, I've made myself a new t-shirt design out of owners manual images: Still, I can't say I didn't warn me. And now I have nice brakes, a new WOF and reg and my 'zorst volume is turned up! What does an AJ6 ('the other Jaguar engine') sound like with half its mufflers removed? Not as good as a garbage Rover straight six ironically, but stay tuned! * Not really. Nobody died. Geez.
  19. 37 points
    Oh yeah and old great uncle Lin had taken the head off around 1988 to fix the spark plug threads (apparently pretty common/easy to cross thread) dont know why but he never put it back together after installing helicoils? He died early 2000s so it’s been sitting in a shed for 30yrs, so there’s a bit of work to do gave it a couple of washes today and wheeled it into the car port will start making some room in the shed to store all the bits/sort out if all the motor bits are present
  20. 37 points
    No work that can't wait till tomorrow, sun's out, 20 degrees, not a breeze. Perfect day for a bit of slap-dash beetle roof painting. * If any of you do this sort of thing for a living, it'd probably be best if you look away now.... Needs a load of clear & a good polish but you get the idea. And that was my rattlecan flake n lace Thursday.
  21. 37 points
    Gave the exhaust a paint with some high temp paint and then tried to assemble it all with out getting too many scratches, wasn't too bad. Bought some new braided rear brake hoses from Australia. The steering rack rebuild kit I got from England was the wrong one so just left the current seals as is and hope they are alright. Sanded it all back and gave it a coat of paint and assembled it back together. Made a new filler tube for the fuel tank and added a drain plug. Since it then needed painting again I sent it off to get powder coated instead. Cut some rubber up for the mounting straps. Just had enough rubber left over for the fuel pump seal. Pulled the engine out and gave it a good clean up. Still isn't the best as some of the aluminium parts are a bit oxidized. Whilst I cleaning the engine I got sick of looking at the hideous standard headers, and ages ago I drew up some exhaust flanges and cut them from 10mm mild steel. So I'm going to try and make some headers with the very little space available. There's heaps of room upwards so maybe try and do some high-rise ones. Started by making some ob-round to round transitions by bumping them on a pressbrake from two pieces. Worked really well, they were quite accurate to size. Need to put the engine back in, cab back on and fit the inner guards so I can build some jigs.
  22. 36 points
    A bit overdue on an update. Undersealed the cab, came up pretty good! Flipped the cab back over and sanded all of the inside and door jambs. Then put some epoxy primer on. High build primed the dash and a few of the panels that will be visible once done, so they sanded up smooth and just sprayed the primer as a surfacer on the rest. Once I got it all sanded down and filled the little bits that needed doing sprayed some colour on. Pretty happy with how it turned out, other than a couple of small sags on the dash, but I'll sand them out later. Picked up a couple of boxes of Dynamat and covered it everywhere I could get it. Made a decent improvement, just need to get some inside the doors somehow and also do something with the gap in behind where the top seat belt mount is. I needed to sort a radiator as the original one wasn't in the greatest of condition. Tried searching for a couple of weeks to find somewhere to buy an aluminium core the sizes I want, but seemed to be pretty hard to get anything. So went and bought one of those universal Chevy cross-flow things that had a core close to what I needed. Cut off the tanks, drew up the radiator and support in solidworks and designed the mounts and new tanks from there. Top tank is angled at the front and with the gap at the top allows me to bring the air intake through there, as there's not really anywhere else for cold air. Drew up some aluminium brackets to mount the electric fan as well. Should clear the engine if I trim some of the pulley bolts that stick out a bit much. Started on prepping the rest of the body panels for clear coating. Left side is sanded with 800 grit which seems to work pretty well, cleans it up nice. The seam at the back was pretty rusty so gave it a sand, rust kill and then seam sealed it. The blue colour I was using for the rest of painting was quite the same as the patina'd paint some had some different stuff mixed up and used it to blend in the repairs. Came out really well! Fixed up the patches where I welded up the old mirror, spotlight holes and the area around the cowl vent.. The sanding brought back some of the original pinstripping around the cab which is cool. Had to clean up this seam on the tray as well since it was rusty and needed touching up.
  23. 36 points
    sticking it together. polishing brightwork and fixing fucked bits. its coming along though. 2018-08-08_08-23-50 by sheepers, on Flickr 2018-08-08_08-24-02 by sheepers, on Flickr 2018-08-08_08-24-12 by sheepers, on Flickr
  24. 35 points
    Been a busy two weeks of knick knacking and paddy whacking really. Had huge progress in the dismantling task, and now have it stripped back to a water blasted rolling body. This weekend I de-loomed it with various difficulties due to Japanese nimble fingers and Mexican wiring swept under holes, while Stephen dropped the fuel tank out which had 1 & 1/2 buckets worth of petrol still in… no auckland tax on that. The front windscreen didn't come out easy however as the rubber was baked more than a christmas pavlova made after a few breakfast rumballs. But with two rolls of $2 tape as support and bare fingers for guidance, we yanked the screen free and the began the painful process of smashing each little piece from the surrounding areas. Even dropped the engine out the bottom to check over if it's worth saving, and the exhaust which is definitely not worth saving. And finally on the progress, I spent a day last week softly caressing the old vinyl rear seats that crack into pieces in your fingers unless you find a 24 year old bottle of Johnsons baby oil at the back of a bathroom cabinet, and massage that into the fragile material until it's overwhelming in smell. Then I spent the remainder cleaning up plastics with thanks to rivalrx CRC suggestion, AKA the new best thing after Autosol. Note grubby handles. Got new door cards from Australia - $140 free shipping bloody impressed and awesome business card to match. Bonus items found hidden this week were a knife down the wheel arch in boot, an Escort window winder, and a monopoly house under the fuel tank. Kind regards, rotorhoe
  25. 35 points
    Talk about cutting it close. I finished everything on my list of stuff I need to finish before my road trip tonight, and I leave in the morning!! Not much of an exciting update, just tidying up the last few things. Did some road testing over the weekend and tweaked the ECU a little bit. I found that some of the settings like the overrun/deceleration fuel cut and idle had too much of a deadzone for my application. For example the overrun fuel cut was set to cut the fuel if the TPS was below 0.7% but the problem is that because the car is so light and the engine is so powerful, you are quite often cruising around at 0.1-0.5% throttle. My TPS is really accurate and stable so I just turn all that sort of stuff way down so for the fuel cut or idle the TPS needs to be below 0.1% now. Drives like a dream now, it has such awesome throttle response with the ITB's. Also did some tweaking with the brakes. Reconnected the booster and then wound the brake proportioning valve to the maximum reduction, which is 57% and the brakes feel really great now. Super happy with the brakes now. In other last minute things. Got the spare tyre fitted. Had to make little drop downs for the front because there used to be a 155 width tyre and now it is a 205. Still fits sweet in between the fuel system and exhaust. Put on some clear protective take where the air cleaner touches the bonnet. In real life you can't see it like you can in the photo Made a little rubber mat for the back so everything won't slide around as much on the trip. I also go on road trips with my friends and their dogs so it will be nice and easy to clean. Made a new bonnet stay like the one on my other Avenger And a little holder for it. Also went to a car show in the weekend. Got really good feedback. people were pretty impressed with how well everything fits in there. And YAY!! Road trip tomorrow. It's been an epic build and I am so stoked I got it all finished the night before I leave. Such a relief. Still more to do when I get back, like the proper wheels, but now it is time to enjoy the car!!
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