Archive for July, 2008

Day 31 – Back to Business

It’s been a while since we did any work as we’ve had quite the hectic week. We’re back on task now though, and the next step is to get the last of that floorpan out. We wheeled the buggy around onto the driveway and powered up the airline. As it’s being so long I’ve even got some video for you.

Getting the floorpan edge off it’s welds is supposed to be simple, and for once, it was! We simply wedged the air chisel into the welds and hammered them till they came out. It was then a case of rolling the metal along moving from one weld to the next. We got 3/4 through removing the first pan in about an hours work which isn’t bad going. Time to get the new ones ordered and ready to weld into place.

We also will need a new copper brake line made up because the old one needed braking away to get the welds out – it ran right on top of them. It does look like whoever last changed the pans went a little over the top with the spot welds. There is meant to be one every 6-7 inches, we were finding them every 1-3 centimeters :S

There is a few new photos in my Flickr set

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Day 22 – Shiney

Not a lot to report today. We’ve got the buggy moved thanks to the driver who moved it for us first time. It’s now sat on our front lawn tucked into a corner. We didn’t perform any real work over the weekend as we were working on my car ready for a wedding next weekend. I did try some metal polish on the exhausts which is probably worth mentioning. Only about 5-15 mins work, but it shows what can be done in such a short amount of time.

Here’s some before and after shots:

Before: After:

Before

Before

After

After

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Day 20 – Rust is evil and must be punished

Equipment all set, lets get to it

Equipment all set, lets get to it

Right, the big day has arrived; all the tools have been assembled and it’s time to start cutting out the floor pans.  Replacing these is one of the most important, longest, and hardest jobs in the project. So down to the lockup we went, pulled the buggy out, lifted out all the rubbish and took the shell off. Read the rest of this entry »

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Day 19 – Diesel Power

Well in most aspects of life I am all about petrol power, but when it comes to generators then it’s time to turn to the dark side.

After last nights miss match I have pulled some more strings and found someone who is willing to lend us a 20 Amp diesel generator; now this should power the airline a bit better.

Been and collected the beast with another good mate Brian tonight. He is definitely a top mate and someone to have in your speed dials. He is the sorta guy that you phone and go “Any chance, for no reason you have a massive generator in your garage?” and he goes “No, but give me 10 min’s and I will find you one.”

True to his word 5 mins later he is back on the phone having sorted this for us:

Just a little bit bigger

Generator in the car

Took a bit of wiggling to get it in but it fits in and out of the car.

Right thats it from me for today,

Jon

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Day 18 – It’s Hammer Time

Jon here, well i suppose its time for my 1st post on here. I have spent all my time with the spanners so far.

Not a lot has really gone on today, I borrowed a few tools from my good mate Edd in time to spend the next few days taking out the remains of the floor pan:

Generator and a compressor! problem is the compressor needs 1.4 kilowatts, and the generator supplys 0.4 kilowatts

Generator and a compressor! problem is the compressor needs 1.4 kilowatts, and the generator supplys 0.4 kilowatts

1st we have an airline with a few tools including an impact gun and more importantly an air chisel, that should be handy for breaking out those spot welds. I was planning on buying an air saw to go on this but I may now have to spend those pennies on a different generator.

2nd a generator to run the above airline, just one problem. I forgot to check the ratings, the compressor needs 1.4 kilowatts, and the generator supplies 0.4 kilowatts. I have spoken to another mate and may have secured another generator but this isn’t confirmed yet.

On positive note I was at my local VW garage and tuning shop earlier today, talking about my main car, and the buggy came up in conversation. It turns out that we may have secured a welder to fit the new floors as well as teach us how to weld.

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Day 17 – Guest starring

Robin removing the last few floor pan bolts

Robin removing the last few floor pan bolts

Back to the weekday short tasks today. Painting and the like is definitly a weekend job so we’ll come back to that later. It’s being a fairly successful evening. We’ve taken a major step and got the body off.  Robin “The Persuader” kindly volunteered to come over and help with the removal of the remaining bolts down the sides of the floor pan. 4 hours, and a lot of blood (Robin spent a while this morning researching Tetanus), later all the bolts are out and we were able to just lift the body away.

This revealed a lot more of the chassis and floor than we were able to inspect before (obviously). It looks like we’re going to have to replace a lot of small parts, which isn’t so good considering how long we don’t have. All the major components look like they are in OK condition, it’s just things like bushes, grommets, seals, tubes… in fact every piece of rubber needs replacing. We may also need to replace suspension coils and brake drums, but that’s not a certainty yet.

The whole thing will look a lot less depressing once the old floor pans are out which is happening this weekend. Jon has agreed to borrow a generator and air line off a friend so he’s going to be air chiseling the welds out.

Here’s a look at some of the rust in video form:

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Day 14/15/16 – It’s not easy being green…

http://flickr.com/photos/simongreen_uk/2660904334/

Jay attends the casting day for the new Resident Evil film...

OK gonna do one post to cover the entire weekend. I didn’t have time to do one for each day, it was all a bit hectic! (and depressing). At the time of posting this only my pictures are live, neither Jay nor Jon have uploaded theirs yet. Here goes…

Friday

New tools (Yay). I popped down to B&Q with Jon and picked up a bitching little electric screwdriver and bit set as recommended by Robin. Also got a Random Orbit Sander do to the sanding for the paint work. This was VERY worth getting, and I can see it being used a lot. We didn’t want to do any actual work on Friday as the only tasks we could do at the moment are large ones. We popped up to the car anyway to loosen a few more bolts, tidy some stuff up, collect some tools. I also picked up the H bar that supports the nose cone and dashboard, and the dashboard itself, so we could look at them at the house.

Finally I dug out a copy of AutoCAD with the intention of planning out the new dashboard now we have dimensions for the gauges. I’ll probably get Jon to do this as he’s pretty hot with the CAD software. (Well, compared to me anyway.I can do SketchUp but that’s about it!)

Saturday

Sanding down the nose cone

Sanding down the nose cone

We blagged Jay to bring his Mum’s convertible down so we could fit the nose cone in it sticking out the top. We couldn’t fit it in my car because it’s larger than my boot (being a windscreen it would be). We then sanded it down using the wonderful random orbit sander mentioned above, washed it down with white spirit, and then the weekend of fail began.

First coat of green paint

First coat of green paint

Stupidly, we rushed it. We applied the primer, and it started to rain. Had we being thinking straight we would have at this point rushed it into the garage and finished it another day. What we in fact did, was quickly erect a canopy over it and wait for it to stop raining so we could continue the work. On and off all day we played the running in and out of shelter while spraying game, until finally we had primer, paint and lacquer all on there. It looked a bit patchy, but it did look fixable, so we decided wait for it to leave it overnight and thoroughly set to sand down the areas that were unevenly coated. One thing was clear though, that green is amazing.

Sunday

Oversleeping didn’t help. Sunday was glorious weather, and we missed half the day tired from the day before. Jon went out in the morning to have a look at it, got out all the tools, and got to work. 3 minutes later he had written off 2 sanding pads on the sander and a sheet of 400 grade sandpaper. The combination of the 6 coats, the rain, the damp air, and the rushed job, had turned the green into BluGreen-Tak. It gummed up all the sandpaper and pads and basically just made a mess. I was extremely depressed at this point. Massive waste of money and time on a project with a now even tighter time constraint.

After various different attempts and methods, we found the best way to rid the bonnet of this goo was to combine white spirit and sandpaper to lift it off the surface, and then quickly hose down while scrubbing to wash it off and away. I went and picked up Jay, and we spent most of the day just sanding all of the nose cone back again.

The only progress we made over the weekend was to sand the rust off the H-bar. I would in fact say overall this weekend we made negative progress, wasted a lot of cash. and I got green shoes… You live and learn.

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Potential Disaster

Just a quick note. Turns out the garage we are borrowing to store the buggy in and work on it is set to be destroyed along with all the garages in that block! That puts a serious timeline limitation on this project. More info as we get it!

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Day 13 – Nuts

Rust. Dont ya love it?

Rust. Don't ya just love it?

…and bolts for that matter. Didn’t get as much done today as hoped at all. This evening, we managed to undo 8 bolts holding the body onto the floorpan. That may not sound that respectable, but they were bastards. These 8 bolts were the ones holding the floorpan down the side to the bottom of the body and were stuck in with a combination of rust, anti-rust gunk (great job that did), paint, and voodoo. I was sat inside, the car Jon was on the floor, and there was lots of swearing, pain, WD40, and broken socket heads. We now need new 13mm spanners and sockets. Donations welcome.

There’s not a lot else to say other than that really. I stopped by Halfords on the way home to see what spray paints they held in stock, and picked up some fluorescent green to trial out, as well as some primer and lacquer. We (Jay) will probably test that out at the weekend on the nose cone.

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Day 12 – Gauges

Typical example of a gauge I have no way in hell of affording

I mentioned yesterday that we’d have to replace the gauges. As I’m rained in today, and Jons out at No-Rice, I thought I’d do some investigation into this. Before yesterday, I knew pretty much nothing about how automotive gauges and displays worked. Now; it’s like I’ve swallowed both and encyclopedia and a catalog on the things. They come in analog, digital, analog AND digital, there are so many options, and they range from a couple of quid to thousands of pounds!

There’s even a hundred ways of mounting the damn things. You can flush them in your dash, build them in pockets in your dash, build them in pockets on your dash, under your dash, in your wheel, on your pillars, on a bloody head up display! It’s mental. Read the rest of this entry »

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