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    Body restoration time

    I can't believe it was 14 years last month since I bought my 1st stag (the Mk2)

    The engine blew up the following February and I rebuilt it and converted it to MOD from auto, and to injection, but I was disappointed when I couldn't match the power figures of my TR, being about 18bhp down, which I eventually put down to the smaller bore exhaust manifolds.

    A further fly in the ointment was the bodywork. Despite having receipts for over £4600 of bodywork in the 3 years before I bought it, it soon became apparent that the bodywork had been badly bodged and I ended up replacing the lower halves of both rear wings and the drivers doorskin a year or so later.

    I reckoned there was a very good chance that the front end was equally bodged (MOT tester pointed out vast amounts of seam sealer over the front chassis outriggers but this actually looked better once removed)

    The combination of a disappointing power output and possible extra bodywork (although the car was still very tidy) pushed me into buying my unmollested MK1 which was featured in the Flying Farmers new project thread which I started back in July 2012 with the intention of sorting out the Mk2 when it started to get tatty.

    Over the last couple of years I could see large areas of filler starting to lift on the lower front wings, so I dave decided to bite the bullet and get on with the job.

    Blowlamp and scraper revealed a good quarter of an inch of filler over most of the lower halves of both front wings. Repair panels had been used and to be fair a reasonable job had been done, but due to the repair panels not being seam welded the damp had got behind the filler and dissolved a lot of the steel.

    I was a lot luckier with the front wings than I was with the rears. On the rears the original metal had been cut away so replacement arch repairs wouldn't work, and I had to go for lower half wings which are a PITA to fit due to having to weld the entire length of the wing with the attendant distortion.

    Fortunately the repair panels had been shoved up inside the original wings at the front, and there was an inch or two of overlap. This meant I was able to grind off the repair panels and still have metal to trim off to fit a set of SOCTFL front arch panels. (I did ring Robsport to check their dimentions before I started cutting)

    I started with the drivers side as it was least depressing. I have had to replace the inner arch lip, the rear splash panel and a lump of the sill behind the wing. The pictures shows it in its current state with a couple of coats of white Smoothrite for some rust protection.
    I have still got to do the front of the inner arch and the lower front panel (inner and outer), but these will be done once the outer arch is fitted, I tend to incorporate a few mods to remove rust traps and give more clearance for the 15 inch rims (had to use 195/60 x 15 on this one due to the tyre catching the front panel on full steering lock)
    P1010363 - Copy (600 x 400).jpg
    I have started more cutting work on the nearside which also involved removal of the front outrigger. The picture was taken before this happened. I have also found some rot in the main chassis leg. I will post some more pictures as I work my way through it.
    P1010364 - Copy (600 x 400).jpg
    Neil
    TV8, efi, fast road cams and home built manifolds. 246bhp 220lbft torque

    #2
    Good luck, it's a mammoth job but well worth it! It's worth checking the 'A' posts while you're in there....
    Richard
    Mabel is a white 1972 Mk1½, TV8, Mo/d.

    Comment


      #3
      Good work Neil, there's always a down before the up. At least it's all stuff you can sort yourself - not that I'm jealous

      Please keep posting your progress.

      Mark
      1972 Mk 1 - Sapphire Blue; Original TV8; HID Lamps up front;

      Comment


        #4
        Always good to read and see your workmanship Neil, and it's inspirational to me as I have all this to achieve too. Thanks for sharing

        Ray

        Comment


          #5
          Originally posted by mole42 View Post
          Good luck, it's a mammoth job but well worth it! It's worth checking the 'A' posts while you're in there....
          Too right, I took the courage to poke at the bubbling paint right at the bottom of the screen pillar next to the gutter. Much to my amazement the small screwdriver didn't want to go through the metal

          I might be lucky that side and the damp is just lifting the paint from the gap between the scuttle and the wing. I know it wont be as good the other side as the bottom inch or two of the gutter panel is swelling and crumbling.

          I have welded the outer arch and bottom of wing repair panel into place today, I reckon I have about another days welding in the lower front corner to finish the drivers side, then the far more complicated passenger side will be started. Going to have to remove the radiator first as there is a hole in the rad support panel on the nearside, and I need to get a hammer in there to knock some dents out of the lower front panel which happened some years ago when the other half rammed a high kerb when parking
          Neil
          TV8, efi, fast road cams and home built manifolds. 246bhp 220lbft torque

          Comment


            #6
            P1010369 (600 x 400).jpg
            That was yesterdays welding job.

            Spent 3 hours tonight removing the radiator and cutting out the remaing rot on the offside corner. Got a few days of Christmas related nights out so welding probably won't commence much before the weekend
            P1010365 (600 x 400).jpg

            Neil
            TV8, efi, fast road cams and home built manifolds. 246bhp 220lbft torque

            Comment


              #7
              Coming on nicely Neil, very jealous of your welding abilities which appear to surpass my feeble efforts by some significant margin!

              Cheers!
              Mike

              Comment


                #8
                I have now got the offside front corner welded up
                P1010373 (600 x 400).jpg
                Been busy with the grinder on the nearside, not much difference in the front corner apart from the outer part of the radiator support panel which is beyond help, I will have to fabricate a new bit.
                P1010375 (600 x 400).jpg
                The front chassis leg has a hole, and the outrigger is a gonner. The inner sill is worse than the offside as well. Not going to be short of stuff to do over Christmas.
                P1010377 (600 x 400).jpg
                Neil
                TV8, efi, fast road cams and home built manifolds. 246bhp 220lbft torque

                Comment


                  #9
                  I suffer from DIY envy at all you people who can do so much yourselves. Management thinks I should do all mechanicals from now on as my bright java green machine is only just being reassembled. I can change a head gasket on the Alvis thanks to a wonderful friend who knows Alvis backwards. I also don’t have the workshop space for grand projects.
                  Happy Christmas

                  Comment


                    #10
                    The extra hours of free time over Christmas have been useful.
                    Hole in the chassis leg has been repaired, the inner and outer sill behind the front wing has been replaced and a new chassis outrigger has been fitted. The new outriggers are significantly thinner metal than the originals.
                    P1010378 (600 x 400).jpg
                    I remember an article by the previous owner posted a year or so before I bought this stag. The nearside lower inner arch panel was rusty and IIRC he took the car to a body shop with a new panel and asked if they could manage to fit it without burning the paint on the front wing, and was happy with the result. I'm afraid he was robbed if he thought the panel had been fitted as the panel was original with added seam sealer and fibreglass. There was lots of seam sealer and fibreglass in the bottom corner.

                    The floorpan had been patched over the chassis outrigger, the replacement steel was still in good condition so I managed to cut out the original the rusty original floor pan from beneath back to the welds to get rid of the double layer. Application of a suitable sized hammer knocked the patch down to the level of the chassis outrigger.

                    The inner arch had been repaired previously around the edges. Unfortunately, although it wasn't too rusty in some places, the new arch wouldn't go up high enough to match the swage lines so I had to cut the majority of it out. I have had to approach this side slightly differently to the offside as more metal had to be replaced in the sill and I didn't have a datum for the lower rear arch panel. As a result I have had to trim the lower wing repair panel so it aligns with the rear of the wing and weld the lower inner panel in place to suit. On the other side I was able to hold all the panels in alignment with mole grips and self tapping screws before I started welding.

                    At some time this car had been fitted with wing mirrors which apart from being completely useless (particularly the nearside), I think they also spoil the lines of the car. While I had access to the underside of the wing I took the opportunity to position a small filler plate over the hole and weld up the mirror mounting holes. The mirrors are in very good condition, I suspect they might be originals, so I am going to reuse them on the doors.
                    P1010379 (600 x 400).jpg
                    Next job is the lower wing repair panel which I am going to have to tack weld into place before I line up the outer arch repair panel
                    Neil
                    TV8, efi, fast road cams and home built manifolds. 246bhp 220lbft torque

                    Comment


                      #11
                      A lot of work Neil, I bet it is a nice feeling now you have got this far.

                      Comment


                        #12
                        Originally posted by paul jorgensen View Post
                        A lot of work Neil, I bet it is a nice feeling now you have got this far.
                        It certainly is.
                        I am hoping to get the welding done by the new year but something will probably crop up and slow the progress
                        Neil
                        TV8, efi, fast road cams and home built manifolds. 246bhp 220lbft torque

                        Comment


                          #13
                          I am now pretty much at the end of the welding marathon.
                          P1010383 (600 x 400).jpg
                          P1010382 (600 x 400).jpg
                          I wasn't looking forward to investigating the rot in the nearside screen pillar. When the gutter was removed it wasn't as bad as I feared with the rot being confined to the double skin area under the gutter panel so it wasn't too difficult to repair.
                          P1010380 (600 x 400).jpg
                          P1010384 (600 x 400).jpg
                          I am not sure if I am going to bother reffitting the gutter. I haven't got any fitted to my MK1 and it doesn't suffer any leaks.
                          Being able to seal the gap between the wing and the screen pillar and thus keep most of the water out of the under wing area seems a better idea than having a gutter dumping water between the panels.

                          Next starts the laborious task of paint stripping an filling.
                          Neil
                          TV8, efi, fast road cams and home built manifolds. 246bhp 220lbft torque

                          Comment


                            #14
                            Nice work Neil!

                            Happy New Year!
                            Mike

                            Comment


                              #15
                              Nearly a months worth of preparation later I am beginning to get somewhere.

                              The inner arches and as far back as the first chassis outriggers has been given 3 coats of two pack epoxy. I have used this stuff on the chassis of my TR and also the floorpan of my Toledo. Once I have the body painted I will cover this in a coating of Schutz for extra protection from stone chips.

                              Mission creep is setting in unfortunately. The original plan was just to do the front panels and bonnet and touch in the bottom of the screen pillars until I got round to painting the back half of the car next year, and I might not even have bothered that if the paint had been a good enough match.

                              However, I found the paint on the screen frame wasn't very well bonded to the original paint. There were also an assortment of spiders legs running under the paint above the screen and under the chrome screen capping. This meant the screen had to come out so I ended up removing the screen, doors and most of the interior trim. This does mean I can do the front end properly, and it also makes sense to do the doors while they are off.
                              Trouble is, there is also a tiny bit of paint lifting on the offside rear wheel arch which I could possibly touch in.

                              In the end I will probably end up respraying the entire shell since the interior is out of it. I am hoping that a miracle will occur and the paint will match well enough on the boot lid as I only resprayed that about 2 years ago.
                              I will probably do the inner rear arches at the same time as they just have Waxoil underseal on them at the moment, and I will go for the 2 pack epoxy plus shutz route on that end as well.

                              The floorpan needs repainting at some point, but I intend to ignore this until I have another engine built for this stag as the current engine only produces a guestimated 180-185bhp and feels rather lack lustre compared to my 256bhp stag.
                              When the engine is out I will mount the shell on my rotisarie and remove the rear suspension etc to do a proper job without lying on my back, and also give engine bay a much needed respray, but all this is a year or two away yet.
                              Pictures show the stag in its current state, I am gradually working round the front end filling low spots with extra coats of primer and suspect it may be possible to give it the first coat of Topaz tomorrow to be able to see any other low spots and most importantly at this time of the year, seal the porous primer against moisture. P1010402 (600 x 400).jpg P1010404 (600 x 400).jpg
                              Neil
                              TV8, efi, fast road cams and home built manifolds. 246bhp 220lbft torque

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