Thread: New Project...

Hi All,

The seat-box was in a pretty sorry state when I removed it from the car. The previous owner has butchered the passenger section when he installed a second fuel tank.
Basically the passenger tool-box area was cut out with a welder - leaving a big hole and lot's of rough edges.

I have removed the fuel tank for multiple reasons (poor fitting, poor plumbing, fumes in the cabin).
To put petrol into this tank you had to remove the passenger seat base, pull up the seat-box lid, unscrew the petrol cap and then poor petrol directly into the top of the tank. Not sure how legal/safe this set-up was...

The intention is to put the seat-box back the way it should be (roughly). With the help of a mate we achieved the below over the last few days.

Here is a picture of the seat-box when I removed it from the car:


Here are some pictures of the seat-box after hours of sanding:


First step was to grind back the poor cuts (you can also see the hole that was used for the fuel line in this pic:



We already made a large repair panel for the bottom of the seat-box and painted it:


Made up a small plate to cover a hole that had been cut into the seat box:


Plate installed (pop-riveted and Sikaflex):


The repair panel installed (pop-riveted and Sikaflex):


I also did a few other small jobs. Here is the exhaust bracket (before)


And after cleaning (I will paint the various brackets)


Here is the painted Tow Bar Plate:


Here are the painted brackets for the tail-gate arms:


That's about it for the moment.

Regards,
The Grey Ghost

Hi All,

Some work done over the last week - the weather has been good enough to get some painting in..

Seat box painted:



Top Tail Gate painted:



Exhaust bracket painted and re-assembled:


Brackets for the door handles - before, cleaned, painted:




That's it for a few weeks - work is getting in the way!

Hi All,

Some more work done of the last week and a bit...

Here are the front guards - BEFORE:





I decided to get these panels sand blasted - because of all of the nooks and crannies... After Sand Blasting:



After some minor repairs, and now painted:




I decided to clean-up the leaf springs - before:



Sanded/Cleaned:





And painted:


I've only done 3 springs so far - and will tackle the fourth during the next week or so.

Hi All,

Decided to Sand/Clean/Paint the body-skirts today. Here is a before picture of the skirts:


Took them apart and did some minor panel beating.

Here is a before/after pic of the ends:



Here is a before/after pic of the brackets:


I will work on sanding/cleaning the main sections during the week.

Looking good but to be totally honest i would have replaced the tail gate with a correct series 2 unit, series one LWB rear tailgates are imposiable to find esply ones that are in good cond!

Hi All,

Well progress has been a little slow of late. I've been working 7 days a week for nearly 3 months now, and I have to admit that motivation has slipped a little!

Work is now back to normal so hopefully I will get back into the swing of things.

Here are the painted end-caps for the side skirts:


Here are the painted brackets for the side skirts:


Here are the main part of the side skirts - sanded, ready for paint:



Here is the replacement seat-box lid - before and after sanding:



Here are the hinges for the seat-box lid - before and after sanding:



Here is the replacement LHS mud splash panel - before and after sanding:



Hopefully more to follow next week!

Hi All,

Well I managed some more work on Roger this week...

Here are the hinges for the passenger seat box lid - painted:


Here is the passenger seat box lid - painted:



Here are the two, married back together:


Here is the LHS mud splash panel, painted:


Here are the skirts - painted:



There is a bracket that holds the end-plate of the skirt on. The brackets that I have are rusted and all bent out of shape. I decided to make some brackets to replace these.
Here is the original & the one that I made up.



I noticed that on both skirts, at the front of the skirt - the aluminium around the front most hole used to bolt the skirt onto the car - has small cracks in the aluminium. I assume that this is just fatigue on the metal.
Having no welder (or skills to use it) - I decided to make up a small aluminium plate that I pop riveted over the affected area to add some strength.



Here are the end plates assembled !!


Here are the nuts/bolts for the skirts - before & after sanding/cleaning:



Next job is to re-assemble the the brackets for the side skirts!

It's amazing how much time all of these job take up...

Lucky I am not on a time-table

Good to see you have some time to get back to it mate. Are you around next weekend at all? May be able to finally make it up there to pull the engine out if you want?

Cheers - Gav.