I've not forgotten what you said about beams to me and i will certainly contact you when I get round to building mine. I've kind of put it on a the back burner until i sort all the rust out.
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[Car_Overhaul] An Idiots Adventures. 205 Destruction
Posted 04 October 2013 - 07:23 PM
What did you use to strip the underseal off? Was it just a wire cup brush? Got this to do once I get the tank off.
I've got a near full tank of stale fuel to dispose of, so if that goes remarkably wrong you should see the flame front pass by Gourock.
Posted 04 October 2013 - 11:07 PM
Bogye, won't be long to bonfire night, dispose of the fuel then. Top tip, rag in the filler hole of the tank, drag to most hated neighbours lawn, pour.
I mainly used one of the flat twist knot wire brushes on a grinder to get the worst off. I then went down to various shapes and sizes of the thin wire brushes in a drill along with a 20mm cup style twist not for all the really clogged up hard to reach areas. After that it was a hand job with paint prep pads bought from Halfords.
It's a filthy, long, soul destroying job but the results are hugely satisfying. I got the metal much cleaner than in my previous pics but I never took pics due to being in a huff with the whole process.
Posted 05 February 2014 - 11:45 AM
Update time. It feels like a very long time since the last update so am surprised it was only October.
So, with the rear of the car sorted I moved onto the front. I knew at least one wing was gubbed, there was a bit of rust on the near side (i need to google these terms every time) chassis leg and a bit of a hole in the floor near the front of the handbrake caused by the hole for the self taper that fixes the handbrake surround just rusting out. I learned at least one lesson with the back end though. Don't strip all the undersell until you've fixed the known holes. Cleaning all the steel and leaving it exposed the last time was stupid.
So front end off
From reading here I expected the headlight panel to be partly made of brown dust and I wasn't disappointed.
Of particular note is the hole near the tow eye. I'm positive there was a bit of an accident with this side at some point. The outer wing panel is definitely original but it has been off at some point as it had weird spot welds near the headlight and it's had a crap paint job. There was also a bit of welding near that tow eye which was so crap it actually gave me confidence in my own welding. The wheel arch and back of that panel had also been covered in some sticky black s*ite which had been useless at preventing rust hence the inner wing being a mess.
The dodgy repair
Welds drilled out and crusty panel binned.
The offside wing wasn't bad. Bad enough to merit cutting some of it out though.
Unfortunately I still haven't taken any pics of this side repaired but it is repaired, i promise.
Then the near side which was a wee bit more involved. The return on the end of both bits along with a fair bit more of it had been blown away by a pie of the finger and a gentle breeze.
The rot spread pretty far and the addition of that ladle shaped indent under the washer bottle persuaded me to just cut the lot out. Cut it, made a template out the cornflakes box, transferred it to steel and made a panel that sort of fitted. I should probably have checked but i really hope the ladle shaped bit didn't have an important purpose. if it does it will be hammer time.
The vertical part of the inner wing was also pretty bad and I didn't really fancy trying to make the bowl bit at the end. So before melting that other bit in I posted a cry for help and Juttie205 kindly supplied a healthy replacement panel left over from his Dimma project (my next born will be named juttie205 in return). So it was safe to cut it all out.
At this point I stood back, looked at my handy work and started to doubt my sanity. Being someone that does nothing even remotely like this for a living (or at any other point in my life) I started to think about possible future pitfalls with the repairs. Mainly wings sticking out 2 inches with bolt holes not lining up and boss eyed headlights. I should probably have just drilled all the spots out on everything here and replace the whole lot as full panels but I didn't fancy trying to source all the panels and for some odd reason I'm better (less awful) at but welds than I am at spot welds.
I cut the needed part for the new panel with a big overlap and bolted it on with the outer wing to ensure it lined up at the end. I thought I was pretty bloody clever coming up with this.
I then cut through the 2 panels with them bolted and clamped together. Unfortunately the panels must all have shrunk when i left it for a few days because when I went back to start welding it this panel was about 1cm to short. Fortunately enough to bridge with weld using a copper plate. I took a pic of this but i'm not showing it as the bridging welds look awful, they cleaned up well though.
So this side all got welded up
So with that all done it was on with the sensory depravation gear and back under the car for some hot grinder action
This update was long over due. I'm a fair bit on from this now with the front half of the car all cleaned off underneath now. The gearbox is out and everything is off the bulkhead to give it a proper clean. The headlight panel was welded on last weekend and i'm hoping to get the first coats on the underside this weekend. Pics of all that soon.
Posted 05 February 2014 - 03:40 PM
Posted 20 August 2014 - 10:58 AM
Good god! 6 months since I last updated this. Apologies for this being so long yet again. I'm a waffler and I guess if i updated more regularly it wouldn't be so bad.
I’m afraid this update is going to be rather disappointing for 2 reasons.
1. I started a new job in April and as such have less time to fanny around with the car. At best i manage about 3 hours maximum a week. And when that time is split 20 minutes trying to figure out what a part is and where it goes, 2 hour actually making progress, 20 minutes just standing staring into space with my mouth open and 20 minutes trying to wash chemicals/bits of metal out of my eyes or running around screaming looking for plasters. progress is slow.
2. My new work were stupid enough to send me to Paris for a week equipped with a company credit card. As you do I used it to get blind drunk the first night I was there, took a trip to the seedier side of town and ended up getting my phone taken by a pick pocket. WTF has this got to do with the car you may ask. Well, I had all my photos on my phone (not backed up). The most worrying thing about this is that I had been taking pictures of every plug, wire and hose as I was removing them so i could reference it as i put it back together. This means I’m going to be asking a lot of stupid questions over the next while.
Anyway, onto what’s been done.
The underside and arches are all now fully coated with Upol gravitex. It's given a nice OE finish despite it being the first time I used a compressor and only discovering that you could adjust the pressure 2 weeks after doing the job. I now have a full collection of Jackson Pollock style tools and 2 matching bikes.
Engine bay and interior painting
The engine bay is all painted up. Unfortunately I don’t have the space to remove the engine so i had to get creative. I’d removed the gearbox as i wanted to sort an oil leak in that area. With the subframe and all that s*it off this meant the engine was only on the one mount. I rigged up a load of blocks and props like you'd see on an indian building site and unbolted the remaining mount. I then just lifted the car up clear of the engine without moving anything. Sadly those interesting pics were on the nicked phone.
Interior floor is also all painted up (same goes for pics here). I’m using the car as a shed at the moment so pics don’t exactly show this at it’s best.
I took the box out so i could replace the input shaft oil seal. I'm guessing it was leaking because the bell housing was full of oil that smelt like ale hangover farts. Didn’t realise you had to get the clutch fork off for this and not realising you could punch the pin out i decided it was best to just get the grinder out and destroy a perfectly good fork. While i was in there i removed the clutch (which was relatively new) and the flywheel to replace the crankshaft oil seal. I don’t think this needed done as that area was clean(ish) and dry(ish), I did it anyway so sods law says it’ll now pish oil everywhere.
Corner truly turned
last weekend was a benchmark for me as i finally reunited the gearbox with the engine. The engine itself still looks pretty manky in the pics. I know it looks weird next to the overly painted up gearbox but after several days cleaning crap off the block i decided it was as clean as it was ever going to be without fully stripping it and getting it blasted. My only source of cleaning was elbow grease, a job lot of Astonish and a steam cleaner i stole of my mum. As it still wasn't clinically clean i figured i wouldn't get a good long lasting paint finish and patchy flakey paint would look worse than it's natural, cleaned up finish. I decided the same for the head and also the thermostat housing and the bit that goes above that (so clueless i have to look at pics in the haynes manual to find out WTF things are).
The engine bay is in no way done (obviously since half of it is still lying on the floor). Still got more cleaning, painting, plating and polishing to do. Not to mention tidying up my dreaded loom. Expect lots of pictures of that saying "what does this plug into" in the near future.
I've started putting other bits on such as the fuel filler, fuel lines (which after reading about the nut and olive costing £150 I decided to "preserve" my relatively good old ones). Few wee bits in the bay including the pedal box and that big round thing that bolts onto it. I got a local guy to make me up some polished cupro nicel brake lines (I know but when i added up buying the materials and a decent flaring tool this worked out cheaper). I plan on getting the big front to back pipe shaped and on soon so i can get the tank back in, then it will be beam time just to balance the cars weight on the stands.
I was given a home plating kit by my dad who had found it in a box of motorcycle bits he’d robbed from someone. Unfortunately the yellow passivate had burst open and destroyed half the stuff including the instructions. I managed to source all the chemicals via the internet but as a result I’m probably on a CIA watch list now. I followed instructions found on an Alfa forum that seemed to have been translated from another language so i just made a lot of it up.
Possibly unsurprisingly I’ve had mixed results with the plating due to a number of factors. Using the wrong power supply, not getting the bits clean enough, leaving bits in too long etc. Most of the bolts and small brackets have turned out ok but i couldn’t be arsed doing all the washers so just ordered a load of new stainless ones along with BZP flanged nuts for all the small non stress/heat critical areas.
I've been making further use of that steam cleaner and job lot of Astonish on various other bits so have all the beam bits, sub frame and lots of other wee bits and pieces all painted up. I was going to Powder coat some of these parts but after talking about it with a local fabricator who was doing some railings at my house he said it's generally not brilliant. it made sense that long term if accessible bits were painted it would be easier for me to do any necessary touching up in future to keep them good rather than having to strip everything to recoat. Could be misguided but hey ho, it's done now.
Lots of stuff still to do but it feels like the corner has been turned now and having a lot of the parts all sitting looking like new ready to go back together makes a difference. It feels like it's really been 6 months of prep.
Thanks for reading if you made it this far.
Nice OE orange peel look by sheer dumb luck more than anything else
Sparkly interior now being used as a shed
Engine kind of sort of in and a few replated/cleaned bits
Box in. I bolted this all together last night and put a new mount in. Can anyone tell me what size nuts I need for the mount? Are they regular sizes/threads which ones were nyloc?
I had trouble with the clutch fork arm pin fouling the box as it turned. I solved it by managing to squeeze a dremel into the are and taking the tip off the pin. now the box is in i see the arm wouldn't even have went round that far anyway. Bugger!
A nice blurry picture of some successfully plated parts
Posted 21 August 2014 - 11:36 AM
Great stuff - looks like good progress. I seem to have the opposite in that I have a load of photos on my phone but no progress!
Tried the parts plating too - your's looks good, although mine did too until the 'balance' of the electolyte went all to cock and the later results looked more like your Jackson Pollock tool set. On the flip side if I ever get into tropical fish, I've got half the gear now to get started.
Posted 16 July 2015 - 10:00 AM
Posted 16 July 2015 - 10:17 AM
205 is looking good though and it's always encouraging to see it (slowly) coming back together again.
One thing I did spot is that there looks to be a seal/cover missing off the top of the steering rack, just below where the lower column clamps on. I think it's more a dust cover than anything, but probably best fitting it if you have it somewhere in the mountain of parts that's likely piled up awaiting refitting.
Who did the plating btw and roughly what did they charge, as I've got another load that needs doing and the last place that I used, whilst the results were good, were quite expensive and lost several parts (largish bits, not just the odd nut or bolt which would be more understandable)?
Posted 16 July 2015 - 10:51 AM
Thanks Anthony, and thanks for your help with the parts you've supplied so far.
Are you talking about a seal/cover that goes over the point where the big oily bit comes out the top of the steering rack? I noticed a cover on here on a pic on someone else thread but i never had one on mine. I will need to try to source one.
I used this guy for the plating http://www.electroplateuk.co.uk All the stuff you see in the first pics plus the sump and a few other bolts and brackets not pictured cost £30. A few people on here recommended him and I'm very happy with the work. You probably won't have the most reassuring conversation with the guy on the phone as he just said to me to pop in or just send the stuff in the post and he'd take a look. He was friendly but was shouting over a machine and didn't seem to want to know much about what I was sending. He didn't lose a single nut, took him about a week or so to call back (this time a more friendly chat) and say my stuff was boxed up and ready if i wanted to send a courier. I sent a courier and he requested I send payment by just sticking cash in the post. Old school.
Posted 16 July 2015 - 11:22 AM
Thanks for the recommendation on the plating - I've seen the company name mentioned on here before by a couple of other members and the pricing certainly sounds pretty reasonable to me. I'll certainly give them a shot for the next batch of bits
Posted 23 July 2015 - 08:44 PM
Progress looks excellent on the car. Really putting my complete lack of progress to shame. Need to find the motivation to do the hideous underseal stripping... A task list is what I need ....
On the flip side, son no.2 is 6 months old, so that's another pair of hands on the way for the fiddly reassembly jobs!
Posted 24 July 2015 - 08:53 PM
I'm currently putting all the plumbing back in and can't figure some of the hoses.
1. The hoses from the top of the expansion tank. The on on the left goes to the front of the car then across to the drivers side to top of radiator. Where does the one on the right hand side go? I'm guessing bottom of throttle body or the tap thingy next to thermostat.
2. I have a short S shaped hose (about a foot long) where does this go? My best gues is its actually this that goes on that wee tap thingy and other end to left hand tube underside of throttle body?
Can anyone confirm please?
Other question. Pipe from the back of the SAD goes to one of the pipes on the air inlet right? Pipe on the front goes to the front bottom of the inlet manifold?