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Discussion Starter · #541 ·
Update on the pedal box. This has grown another (lower) panel which now supports the line-lock solenoid.



I've made AN adapters for the fluid feed on both the brake and clutch:



Brake pushrod (made from the distributor shaft offcut!) with adjustable rose-jointed pivot.



Just the clutch clevis to do and that's another bit finished!

 

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Discussion Starter · #543 ·
Dear diary,
It has been two weeks since my last entry. Summer has officially started here in NZ and we're currently enjoying temperatures in the high 20's. Time to do some welding!
Here's the old parcel shelf. Heavy, rusty, horrible.



In it's place is now this. Made from the shell of an old washing machine (yes, really), and lighter than the original.



"Why do you need a parcel shelf?" I hear you all say. It's because on the other side of the panel is this:





It's an old bonnet catch from some kind of Nissan. The remote opener will be either next to the drivers seat or under the rear apron.

The bootlid has an adjustable striker pin and the safety catch 'strap'



The boot in it's fully closed position:





Starting to look neat!
 

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Discussion Starter · #544 ·
Door handles

I (briefly) thought about using the original interior 'door furniture', but then the desire to drill more holes took over....



The handles themselves are made from offcuts of 5mm aluminium, and are exactly the same size and shape as the parachute release handle.
The mounts are plate from 'the' old fire surround and the pivot boss turned from offcuts of steel from the track rod.



Soon after getting to this stage it became clear that the shape of the mounts wasn't going to work, so this is 'evo 2':



Mount welded into door along the original door lock channel:



Yeah, that does it:





And just for giggles, here's what the original looked like:

 

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Discussion Starter · #545 ·
Necessary repairs.......
I bought the engine out of an accident damaged vehicle, and whilst 90% of it is undamaged, the right-hand cam cover must have taken a hit.





I did have all of the pieces, but I don't know where :beuj: so using the bits I had I started reconstructive facial surgery:



Made up some infill bits. 'Woo-Hoo electric glue' so sang David Bowie, though I could be mistaken



And after all of that mess is cleaned up:





Unfortunately the cover is made from some really crap metal which welds a bit like Mazak, and has left a few small 'craters'. These will have to be filled, so I guess the covers will now be painted rather than polished.

Still, whilst I had the glue gun out I thought I'd stick one of these on for the engine breather:

 

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Discussion Starter · #547 ·
Nice work Trev, most people would have chucked that cam cover. I like your philosophy of using whatever is to hand and repurposing things.
Thanks Neil,

I actually enjoy doing it. When I started this build I knew there would be sod-all money to spend on it, so 'budget' was the only way to go.
Have to say though, that I couldn't have done it without my employer allowing me full use of the fab-shop (including the AC TIG :) )

I'll keep posting if you keep looking!
 

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Discussion Starter · #549 ·
Up on the roof!

A job I haven't been looking forward to, but a few days off over Crimble and the New Year gave me no excuses. I present , therefore, the roof insert:
For those of you at the back that haven't been listening, the roof insert panel is cut from a Ford Falcon bonnet panel. This was bought (very cheaply) when I was contemplating making a flat bootlid panel (oh those halcyon days!), but when I put it on the roof for storage it was obvious the shape was pretty close.
So here it is cut to rough shape:



And after a preliminary panelbeating to remove the worst of the swage lines:



Drop it on the car and it follows the shape soooo well:







Plug in the welder, and after a bit of TIGgetyboo:





Grind, beat, grind, beat repeat:







Inside shot:



The last time I did a Pop roof insert, I made it from a flat panel and used a MIG welder. This has been a lot more pleasant to do!

Whilst up high I thought I'd sort the corrosion around the drip rails. I could have just thrown a bucket of filler at it (as the last 'restorer' did) but I hate rust. Particularly hidden rust.
Cut & grind:



The right-hand side was an absolute b*st*rd as it had been welded and brazed to the body (over the rust).



I don't like the 'shaved' driprail look on Pop's so the rails will be going back on after the repairs are done, providing I can work out how to make new ones!
 

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Discussion Starter · #555 ·
Many happy returns.....

...Boot orifice returns that is.....

The bootlid, hinges and catch are all made and work well. Now to sort that horrible gap around the lid and give something for a seal to sit in/on/against.



I dredged these panels from the metal pile. These were made from an old conduit and were initially folded to make sill panels, but never used.



Slice, hammer, hammer and suddenly it's the right shape!



Easy! :) Now to make an exact mirror image :(





Weld weld, grind grind





More to come. Keep watching!
 

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I try not to clutter up people's blogs with 'looks great' posts so once a year -

Happy new year and thanks for all the posts, I really enjoy your build. Keep up the good work.

If you are ever 'down south' look me up.
 

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Discussion Starter · #557 ·
With it all welded it starts to look OK



But inside was less smart:



So, and here's where it gets interesting for those of you who enjoy 'upcycling', I bought this steel shelf from a charity shop for $1



Which I then cut the edges off, this gave me this shape section:



Flattening off the shortest return gives a nice, smooth edge for the boot seal:



Then more beat, beat, beat until the shape is right:



Added these small infill panels at the bottom of the returns



Then weld in the newly made shelf edges:



Slap on a bit of red-oxide



Looking very factory



Hours and hours of work just so nobody knows it didn't come out of the factory like that. I must be a special kind of stupid! :shake:
 

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legendlives; Hours and hours of work just so nobody knows it didn't come out of the factory like that. I must be a special kind of stupid! :shake:[/QUOTE said:
I'll let Wayne know to have a look then 'nobody' will know :lol:
 
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