DUKE

[Deleted]

and yeah duke is on a budget as i'm trying to get him done while paying off the new focus

[Deleted]

right he's back in a working garage

got spare doors to play with

and engine ready to plonk in almost when the body has bee cleaned up a bit







ok to do list time

1. clean and strip back rust from bulkhead
2. clean and repaint subframe
3. strip clean paint and reassemble front suspension fitting new hilos
4. remove brace bars & fixing plates clean and paint
5. adjust brake lines
6. cut out stupid dead lock plates off door frames.
7. repaint and rust treat floor
8. remove windscreen and rust treat frame
9. remove rear windows and rust treat frame.
10. strip new doors and prep for paint
11. get body worker bloke to sort out 'A' panels, fit cavity closers and align the front properly and spray all rust treatment and new works
12. sort out exhaust run
13. clean and and paint new engine
14. strip and rebuild clutch
15. fit and plumb up engine
16. fit all new parts purchased a year ago
17. fit halogen front lights
18. wire in new revers light
19. fit interior including sound system
20. strap down petrol tanks
21. adjust rear suspension

[Deleted]

more stripping this weekend

this time it was all the ancilary bits off the old engine and the clutch and flywheel assembly






work was going well till i found a fist size rust hole in the drivers side front wheel arch / bulkhead / a panel

looks like the body repair just got much bigger

and of course with duke looks like the previous owner covered the rust patch over with thin sheets of metal held on with spot weld and wite silicon

oh what fun

[Deleted]

This weekend i got fed up dealing with the zombies at Halfords who couldn't make the paint even after going in there with all the paint codes

so went to a proper paint shop and got an aerosol can made up as a tester

spot the sprayed patch


here’s a hint it's over the messy weld to the engine steady bracket and the over spray can be seen everywhere

also decided to tidy and rust treat the floor


the yellow aint was from where the floor was replaced and the panels repaired 3 yrs ago
one coat of red hamerite direct to rust


then 2 coats of primer





need to go back over a few bit’s where the primer crackle glazed over the red paint but ran out of primer

[Deleted]

thought i'd get on with sorting out the engine so on sunday decided to drain the oil then strip out the old clutch and fly wheel fit a new oil seal and put the new flywheel and clutch system together

got as far as draining the oil in the front garden where there is a handy step to work on

but as i wheeled the engine back into the garage a wheel of the sack barrow holding the engine broke through a gully cover and the hole thing toppled over with me holding it

i've now pulled all the muscles in my right side and i'm in quite a bit of pain

[Deleted]

Day 1

after closer inspection i found those stupid deadlock plates were only riveted on
so out came the hammer and chisel


still have to clean and paint them before i can put the seal back on

close up of the rust hole ... the hinge panels aren't actually atached to the rest of the inner wing they have split with th rust


got the car up high on axle stands and the engine hoist to hold the front of the subframe


stripped out the drivers side suspension

[Deleted]

Day 2
helped my friend fix the tailgate on his rangerover

Day 3

stripped the passenger side suspension



removed the brace bars cleaned the rust off and started painting all the bits


cleaned the subframe started painting it

[Deleted]

Day 4

a few more coats of paints on the subframe and on the various brace bars, suspension arms and brackts.
should be ready to rebuild the suspension

before



After

[Deleted]

Day 5

brace bars fitted


and passenger side front suspension fitted


alsofitted the adjuatable tie bar

[Deleted]

Day 6

finished fitting the driverside suspension
duke finally has adjustable spax with hilo adjustable trumpets and heavy duty adjustable tie bars to both sides



adjusted the brake lines and refitted all the wiring



and sorted the exhaust run so that i can put him back on all 4 wheels

[Deleted]

1. clean and strip back rust from bulkhead part done started crying
2. clean and repaint subframe started
3. strip clean paint and reassemble front suspension fitting new hilos
4. remove brace bars & fixing plates clean and paint
5. adjust brake lines
6. cut out stupid dead lock plates off door frames.
7. repaint and rust treat floor rust treated and started painting
8. remove windscreen and rust treat frame
9. remove rear windows and rust treat frame.
10. strip new doors and prep for paint going to try and repair old doors first
11. get body worker bloke to sort out 'A' panels, fit cavity closers and align the front properly and spray all rust treatment and new works might be doing this myself now
12. sort out exhaust run
13. clean and and paint new engine
14. strip and rebuild clutch stripped
15. fit and plumb up engine
16. fit all new parts purchased a year ago
17. fit halogen front lights
18. wire in new revers light
19. fit interior including sound system
20. strap down petrol tanks
21. adjust rear suspension

[Deleted]

Before


After


i have to do these progress posts to keep me sane

[MiniGT5]

Looking good how long till your back on the road

N

[Deleted]

engine shouldn't take too long but it's the bodywork thats going to have to wait till I either learn to weld and have the time to play chase the rust or save up for somone else to do it

[Miniböttcher]

i had never welded much before i started the mk1, but if you keep practising, your get it and get used to your welder, start on some where which is not seen much