And So It Begins....

[peteracs]

Hi Guy

That was a good buy, especially like the top water rail!

The roof is proving to be a bit more of a headache than you expected.

On the hub, never seen one with only half the splines machined, wonder if this was from a specific car model?

Peter

[SanRemo78]

I might bring the half machined hub and CV joint with me next weekend Peter, I've found another one that I got from Kevin and that's also half splined.... Maybe that car was a 1300? I don't know anything else about those parts other than it was from a Coupe with a filler flap so an earlier car. Somewhere I must have another hub. Mine came with two!

The top water rail has a thermostat in the head, not sure about that modification in a Beta but made sense for a Stratos replica. The top pipe is nice but it'll need a feed putting in for the heater take off from the head and another out to the heater. I don't want to risk overheating a special engine on No4 cylinder!

Guy

[peteracs]

Be interesting to see the hub.

On the takeoff for cyl 4, the mod is very simple and does not need the top rail modifying.

Peter

[SanRemo78]

Roof replacement going nicely! The plan to unstitch it and do the whole skin has gone by the wayside as the frame on the replacement was too far gone. After a bit of thought on where to cut it Geoff opted to cut a section out and fill it with a large cut from the donor roof. Everything was centre marked before cuts were made and the edge of the cut was joggled for a good overlap. He's now drilling it to hold it together with Cleko's before it gets welded up fully. Could not be happier with it so far!

Guy

[peteracs]

Looking good. Soon be on to paint…..

[SanRemo78]

Went to see it today and Geoff was hoovering out the dust. So close to finishing the shell! He did a hitlist:
Aerial hole to be welded up.
Tab on A post front for mudguard to be fabricated.
Tab on outside front inner arch to be fabricated (wing mount hole)
Exhaust mount - remove a sheared bolt.
Minor grinding of welds on inner arches.

Next he's moving on to the bonnet which needs 4 holes plating where pins had been set up.. Doors - tops need rebuilding and maybe bases, boot lid is fine and a minor repair to the battery tray. Middle of September we're going to meet to arrange a suitable day for everything to go back for dipping etc. Time to choose a painter too.

Gulp. This is where the bills really roll in!

[SanRemo78]

Bonnet fixed. Geoff said the rest of the panels will be done this week. Book the dippers! Getting exciting.

Found another NOS part the other day digging around at Hawk Cars…. Sometimes it’s the little finds that make your day!

[WestonE]

Well done! They are rocking horse Poo thanks to the bulbs welding in place they are frequently broken.

[SanRemo78]

The list is getting shorter. Bonnet and both front wings are now done but both required surgery to the bottom and one to the arch lip. One door has a small dent that will need filler as we can't straighten it without removal of the skin. I can live with that. The valance has been straightened but may require a little more teasing when in paint. One door to repair the top of and a few little tabs/jobs and it's ready to go back to the dippers who are coming to collect the car a fortnight today. Hope to have it into the paintshop by the middle of October!

[SanRemo78]

Progress with the spoiler. I've managed to acquire two HiFi spoilers and this one is the better of the two. The fixing method and finish leave a bit to be desired though with 5 captive bolts being fibreglassed underneath the spoiler and holes drilled. No weatherproofing so guess what? They rust. I was going to replicate this fixing method with stainless bolts but decided a more modern approach would be better.

So, I sealed off the surface of the boot lid with parcel tape, laid the spoiler on top and marked the perimeter. Next step was to cut some matting into 2 inch strips and lay it on top of the lid inside the lines, a couple of layers is sufficient I think. Once it was cured it could be carefully lifted off the lid and laid over the spoiler. A lot of careful sanding later and it fitted neatly within the perimeter of the spoiler and could be taped in place. Some resin was applied on each side and allowed to cure.

Next step was to clamp it back onto the boot lid and run a bead of filler between the flange and the lid to take up any slight gaps and give me a neat edge where the spoiler had been damaged over the years.

In order to finish to off fully I just want to put some more matting between the new flange and the underside to stiffen it up a little more. There are a few scratches and marks on the outside that will need a skim of filler to get perfect but it's a rough old thing, a bit wavy in places but will respond well to paint.

A HiFi spoiler really ought to be black, they weren't painted, just the gelcoat finish. But given it's state I'll have it painted body colour in due course and then it will be permanently Sikaflexed to the boot lid.

I'm not 100% sure I'm going to like the look. But it's an option as it's going onto the spare boot lid. I'll make my mind up in due course!

Guy

[peteracs]

Hi Guy

Sadly I never liked the HiFi spoiler, always looked a bit ‘tacked on’ look compared to the VX etc.

Peter

[SanRemo78]

I'm not sure I'm going to like it either Peter but having been given one and also having a spare boot lid it seems silly not to try it out. It's two springs and four nuts to change stand was to store in the garage if I don't like it.

[SanRemo78]

Big day today - spent it at Geoffs nailing panels back on for a dry fit. The wings went back on perfectly but the front valance didn't want to play nicely. The left side lined up beautifully but the right side took some work, it took us a while to identify that the end was flat underneath the headlamp surround when it needs to have a slight upwards curve. Once we'd identified that and teased it back into shape it was apparent that there was a dent in the front of the wing... A little more panel beating and it all came together nicely. The bumper was added to make sure the profile was right. The bumper isn't the one I'll be using, it's damaged/split bent down on the left side but was great as a profile check.

The rear panel on the car is new old stock and I made the decision to have the number plate holes welded up before paint so we think that's the last job for Geoff to do. I'm planning on spending Monday & Tuesday there again with some Scotchbrite pads going over every square inch of the outside of the car and maybe the inside and underside too to see if there are any areas we've missed.

The windscreen was tested to ensure it's going to fit with the stainless trim too, all good which is amazing considering how much surgery has been done there with a new scuttle, pillars and roof work.

Then it all has to come apart again as the dippers want it that way. I may ask them if I can visit once it's done to rehang everything before they bring it back to us. But that may make it too heavy to lift....

I feel as if a light has been switched on at the end of the tunnel today.

Guy

[WestonE]

Exciting serious progress. At this rate it becomes a car in the spring sunshine.

Well done

Eric

[Nigel]

Looking superb Guy.
I had a similar issue with the front valance recently, I also found that
the wing was not correct.

Looking forward to watching the build-up.

Nigel

[peteracs]

Hi Guy

Glad it is all coming together, will be worth the wait.

Peter

[SanRemo78]

The front wings don't look the picture now! I should have taken another picture after I'd spent an hour or so on each one with a Scotch pad. It took all the tarnishing off. I plan to do the same on Monday and Tuesday morning on the rest of the surfaces before a final hoovering to get as much of the dust and debris out as possible. Of course the objective of doing that is to find any imperfections that require welding. There are inevitably going to be areas that need a skim of filler after all the work that's been done. Roof and scuttle mainly. Not worried about that at all!

Guy