Radiator

Hi

Well the weather was glorious so the top was down on the MX5 and we set out north this time, we headed off up the Northumbrian coastal route and ended up in Craster. http://www.northumberland-cam.com/craster/

Craster  is a small coastal fishing village famous throughout the world for is oak smoked kippers and I fancied some for breakfast, and very nice indeed. After the kippers we went for a walk up the coast to Dustanburgh castle. Just one of the many castle on this side of coast.

Lynne and castle

Only around a 2 mile walk and very nice when the sun is shinning, anyone not done the drive up the north coast will surely enjoy it.

Things have started to arrive on the car front. firstly the powder coater arrived with the front end suspension and subframe. What a fantastic job, every bit looks like it is straight off the shelf, I am really pleased I took the advise of my mate Shaun to get it done professionally. I already have a collection of bits ready for the next batch, I shall post photos of the quality when I re-build the suspension.

Next was the radiator, got a call from Advanced radiators and picked it up on my drive north, yet another fantastic job. After seeing what came out of the car to what they where able do it was well worth the £166

Radiator before re-core

After re-core

Next to arrive was the bushes; unfortunately I made a mistake on the Powerflex selection, the tie rod bushes were good as were the lower arm but what I thought were the upper arm bushes when i ordered turned out to be the upper ARB bushes. It appears Powerflex only make the Lower suspension arm bushes and not the upper. So after a talk with Larkspeed I have returned them all. The Flo-flex bushes I ordered also arrived and after comparing the quality against the Powerflex I gave them a ring and ordered the rest of the bushes from them. They may be the cheaper option at around £120 for the lot with stainless inserts and being all bright orange but they look and feel well made. http://www.floflex.co.uk/index.php?cPath=23_40_44

I have carried on with the underside getting all of the rust off and where I cannot grind clean I have used the rust converter. I had a bit of a shock on the drivers side with the amount of repair work carried out, around 3ft of the side panel has been replaced. Also there is a weld on the pipe that hold the bumper bar, I can't see any distortion to the frame work, and the subframe has no evidence of damage but it has defiantly been cut and welded. You may be able to make out the weld in the photo, around 6" back from the square plate.

Drivers side frame

Pass side primed

First coat of chassis black

Both sides blacked

 I have primed all of the frame work and painted with the new chassis paint, I have used the tough black spray on the front arms to get a better finish than with a brush. I shall rub down tomorrow with the green pad and give it another coat, should be well protected on the sides and an extra coat of hammerite under seal on the underside over the chassis paint should give it a lot more years.

I have taken one of the door steps to a sheet metal firm to get a price on stainless steps and new frame work, should get a quote on monday.

A waxoil application gun arrived today so tomorrow I shall give it ago and spray some rust converter into the sections I don't think are waxoiled, I have a 5 litre tin of waxoil to use up so all of the boxes will be getting a good coating.

Paul

Hole Patching

Hi

Been under the car again today, which I suppose will be a recurring theme for quite a while, but first I had to spend the morning driving around sourcing a large gas bottle. I had problems with my welding yesterday which I have found out is called burn back so it was off to Machine mart for new tips and more gas. I was lucky enough to talk to a guy who works there who restores cars and he put me onto a local gas supplier with far more realistic prices than £14 for a 1/3rd litre bottle from Machine mart. I ended up at Ashley gas supplies in Ryton Sunderland where a large pub style Co2 bottle cost £48, £40 refundable on return and £8 per refill; that's more like it.

I also figured out my burn back problem as being the wire feed to low and a dodgy swan neck and tip so I have replaced them, now its just learning the machine, although I am much better at TIG and stick.

I have spent the rest of the day welding patches to the holey parts of the frame work, I uncovered this little lot yesterday. The water has got in between the grommets for the fuel pipes and because it was only a small piece 125mm long no one thought to drill it for wax oiling
 

I got out my dremmel with a grinder attachment to have a look inside.

I have managed to scrape out most of the loose rust and made a large patch out of a couple of pieces of angle iron with a hole drilled in for rust cure and wax oil injection.

It may not look brilliant, but it is underneath and once painted and hammerite underbody sealed will make it invisible.

The exposed holes on the upper chassis arms required a bit more finesse, I tried touch welding the holes but just made it worst. So a patch was cut from some 3mm and welded on, a bit of grinding and ready for vactan and primmer.

I also received a call today that my radiator is ready, so it looks like a lot more driving tomorrow although the powder coater hasn't come through with they promise to deliver today.
Paul

Hole repair

Hi

Got back late Wednesday night for a 2 week break, only today have I actually got down to doing some work on the car, even though you can't see that I have made progress.

I have managed to organize some other things during my time; firstly after many years in my job and many years spending some of the money earned at Halfords I have only just found out that I am entitled to a Halfords Trade card. So any Engineers out there get down with your quals and get a discount on all of those essentials, tools, oil, filters, lamps, all sorts.

I have been trying to track down which radiator is fitted to the Kallista, even though it is stamped Ford I have had no luck so far. I first contacted http://www.aaronradiator.co.uk/catalog/Ford_Radiator-26-1.html which has all Ford models listed with picture and sizes and could not find it there. I spoke to them and sent photo and sizes but got nothing back. I next asked the man who knows these things, (Terry) and he said it was commonly thought to be from a Granada 2.8 but the sizes don't match what is currently available for this model. So it was a re-core, I have found a good firm in Newcastle http://www.adrad.co.uk/ who are charging around £150 for a full re-furb.
Next was front end bushes, I have spent my 2 weeks away trying to figure out the best deal on my budget, I had 3 main manufactures in mind, Superflex, Powerflex and Flo-flex. As always the best is the most expensive so with probably only 2 to 3000 miles per year and no rallying I have plumbed for the Powerflex and the Flo-flex. The Powerflex ordered are the Upper and Lower wishbones and  Tie rods, the Flo-flex are the front chassis mounting and the steering rack large and small. Unfortunately Powerflex do not do the chassis mounting bushes which was the reason I went with Flo-flex.
Costing
Powerflex for all bushes      £84 inc p+p
Flo-flex for all bushes         £44 inc p+p
My first choice for the Chassis bushes were Superflex but the cost for these 2 bushes was (inc p+p) more or less the same as all the Powerflex bushes. I can always change to Superflex in the future for the chassis if I find the Flo-flex no good.
Next purchase was chassis paint, I had started using Hammerite, mainly because I did not know what else to use and it was later suggested to me to try the paint from Ken & Lyn on 01298 814813 who sell they car supplies at the main motor shows. So after parting with £22 pounds I now have 2 1/2Lt of lovely black chassis paint.
Next buy was a Mig welder, I picked up a used Clarke 135TE for £150 locally from Gumtree.co.uk but need a bit more practice,
Well finally got stuck in today which involved the removal of the rest of the Pass side wings and after 26 years they did not want to budge but eventually of they came. The poor car looks rather sad without the wings.

It was out with the wire brush again and all of the other rust removal tools, the Hammerite came of easily and I got well underneath, I have found a number of holes in the members but surprisingly when removing the rubber bungs and sticking my finger in I have found wax oil.

This hole is were the chassis mounting arm drops down.

I made a metal patch, just about to weld it on.

Started welding this one.

Yet more to weld, I'd better stop there as I'm get depressed. 
start again tomorrow.
Paul

Tuesday 6/9/2011

Hi

Been a busy couple of days, I have the steering rack all painted, the gaiters changed and new track rod ends fitted. Looks like new.

No word on the bushes yet, gave him a ring and they are waiting on the new price list.

Suspension parts are still at the powder coaters, SO

I have have bit the bullet and started doing what scared me the most, Wings off.

I started by removing the headlights or trying to, the drivers side came off easy but I am afraid the pass side will need cutting off as they is no way the nut will unscrew. Not a problem, colour coded headlights are nice but www.europaspares.com have some lovely shells in heavy chrome, will look great with matching spots.

There is a fair bit of damage to the hole in the wing, it looks like the ally has broke away and only the underside fibreglass is keeping the hole in place, I shall have to make up a few ally washers and laminate to both sides with araldite. The swivel mount of the headlights is made of steel and was rusty, looks like it has eaten away at the aluminium and the oxide has swelled.

Headlight damage

Next was the radiator grill, made of plastic and not great, I am replacing this with a stainless grill from Bruno to give the front a clean look. Once off the full condition of the radiator became more apparent, I new it would need replacing but did not realise how bad it was, the copper on large sections of the fins was gone, total wreck.

inner side

Outer side

I need to track one down now, should not be to much trouble, it has Ford stamped on but no serial number so a bit of detective work, or of course I could ask Bruno or Terry Borton as I am sure these gents have been replaced a few over the years.

The surround frame I have put to one side ready for my next trip to the powder coaters.

Now that the radiator is out I can see the engine better and it looks like most of the engine oil leak problem has been the rocker covers all along. 5 minutes work when first seen could have saved a messy engine, on the positive side; it ain't rusty where the oil is.

The wings came off far easier that I imagined only 2 bolts and around 10 rivets, the ones inside the grill area were a little difficult to get at and one hidden behind the frame work but being ally they drilled out very easily. Once drilled a long sharp knife slide between the body and the wing and off it came. I shall get the rear one's off later but for now the wing went very carefully up into the loft.

Wing gone

One more wing, strange thing is that there are 2 different bolt sizes, the first wing had 10mm on to the step where as the drivers side had 8mm or BSW equivalent; maybe changes over the years.

The second wing was stuck on a bit better than the first but a little swearing and its up in the loft ready to be cleaned and sanded ready for the spraybooth.

I had already spent yesterday with the rotary wire brush getting the underside frames cleaned up and looking for monsters, and did not expect to find this.

Hidden under the paint and waxoil just behind the wing support bracket on the pass side, so now I know my chassis number or so I assume that is what it is.

I have got most of the waxoil of the sides and only found three monsters and they are all on the pass side. On reading the garage history I got with the car it mentioned a welding job on the car and it seems that it is in or around the same place but on the drivers side about 6" behind where the chassis bush holes are. I only have a stick welder so next time home I shall be looking for a MIG and get these holes welded up before the waxoil injection.

Well that's all I have managed this time home, get the early flight to Heathrow tomorrow for another 2 or hopefully 3 weeks, my wife is already talking about taking some more time of when I get home to climb another bloody mountain, so I am going to get her a boiler suit instead. That will soon put her off taking leave.
Paul

Friday 2/9/11

Hi

Not much done today, the main job is done though; a trip to the powder coaters. Don't know if I got a good price or not but for the sub frame all of the suspension arms, springs, tie rods and all of the other bits and bobs, he charged £100. This includes sand blasting and dropping them of for me. He also showed me the powder coated chrome effect on a set of alloys which looked quite impressive.

I have had the steering rack in the blasting cabinet as I am going to spray this myself, it may not like being cooked. I have also bought a new set of boots for the rack, the old ones looked in good repair  but may not last to many more years. the rack moves nice and free, so I guess the mot fail for notchy steering is mostly down to the steering u/j's. I'll have them out when I remove the engine for a re-build.

Steering rack boots

I have also bought the paint for what can't be powder coated and have settled for Simoniz gloss tough black and black hammerite for the rails.

Have removed all of the waxoil from the hub assemblies and sprayed with the Simonize and they look very nice.

Boots                        £12 inc p&p on ebay

Paint x6 tins               £32.75 free p&p on ebay  

Hammerite 750cl       £8 on the market stall £16 at screwfix, dread to think of the B&Q price

Powder coating         £100

Thats all for now Paul

Thursday 1/9/2011

Hi

Got back home yesterday after a 3 weeker, back on Wednesday for 2 weeks or possibly 3 if any more extra weeks come up; got to pay for the restoration.
Won't be able to get much done this time home as my wife has also taken more leave to climb some more big hills. It was Roseberry Topping this morning, only 50 mile away in Cleveland and very nice indeed, 360 deg views.

Anyway the time away was very productive as I managed gather a lot more information about restoring cars than I started with, so it is stop what I am doing and re-start afresh.

One of the Engineers I have been working with lately and have known for a year or so is (un-be-known to me) a serial car restorer and has been so for the past 30 odd years. He has restored everything from E types to Morgans to MG's and everything in between what he does not know is not worth knowing and goes by the fine name of 'The Dog' or Shaun Licence on his birth certificate.
So following his guidance most everything is to be powder coated, so my week or so work of sand blasting was a waste of time as it is all done by the powder coaters.

The next person I have taken notice of is again Terry Borton, I was going to retain the old bushes, on the grounds of them only doing 35,000 miles and of course expense as I was trying to keep to a £4000 budget. Terry suggested replacing all the bushes while the car is in pieces with Superflex, this works very well with the powder coating as the bushes have to be removed before coating and cooking the metal work.

One other to join the fray is Richard Younger, Chief Engineer from my sister ship. TVR driver and all round piston head who also happens to live only around 5 mile away. I text Richard as I know he loves this sort of thing and he has agreed to help strip and re-build the engine, he also happens to own an engine hoist and engine work station

I have been doing some research on the web for bushes and there seems to be 3 main manufactures, the top of the tree is Superflex, very expensive; Powerflex, moderately expensive and Flo-flex which appear to be at the budget end. I have decided that because I shall only be doing a few thousand miles per year and of course bearing in mind my budget that I shall go for the middle of the road and get the Powerflex. I have been in contact http://www.speedshack.co.uk/ who specialize in 70's 80's cars, giving them the requirements for a Cortina Mk4 and have asked for prices for all 3 makers, so once they get back to me I shall post there quotes as a comparison.

After searching Yell.com and a telephone call I have decided on a powder coater, they are  http://www.elitepowdercoatings.co.uk/ and hope to have everything ready to take to them tomorrow.

Finally got to work late in the afternoon and started boxing up everything I could, I have kept the hub's as I am a bit worried about grit getting inside and also the calipers until I have a word and make sure they can do them.

First job was bush extraction, I already had experience here while working on my MX5 and had also made the tool for the job, not really a tool, just a piece of pipe for the bush to slide into. A bit of 10mm stud bar  a few nuts, washers and a socket and the bushes just popped out. No heat from a blow torch required as on my MX5, easy.

Tool set up upper arm

Out she pops, lower arm

Once set up just tighten the nut on the socket side and it pushes out the old bush.

All of the suspension arm bushes popped out easy then it was the turn of the chassis bushes, the pipe tool was no use here so a bit of brute force was required and a liberal spray of WD40. The brute force came courtesy of my air chisel fitted with the spike tool, I slide a socket over this and attacked the bush, these where pretty tight fits but with the lubrication soon popped out.

chassis

They are surprisingly few bushes to replace as they is no stabiliser bar and drop links fitted as on a Cortina.

Selection of bushes

These are the 5 main bushes, Left to right are, Tie rod, steering rack big & small, chassis, Lower arm and upper arm x 2.

After searching for what else I could include for powder coating I removed the brackets from the steering rack, the brake hose mounting brackets and the support arms for the front wings. You can see from the photo how badly corroded it is under there, the bolts all sheared while removing.

That was all I could think of for the moment but this is just the first shipment to the powder coater's and shall get there tomorrow.

see ya Paul