[Car_Overhaul] My Reshell Project

[Simes 248 2 Cars]

Not much done recently, but a long list building up.

What with a wedding, a honeymoon, a change of career I think I've managed to wash the car and do about 600 miles since the last update.

Hopefully something will be done soon.

 

Something of note I did buy some POR15 paint to try out on the battery tray...although it's still sitting in my workshop unopened.

[Simes 248 2 Cars]

Update:

 

 

Removed the battery tray a couple of days ago and treated with the POR-15 black paint I bought last October - see above

It's come up really well, dries and finish is better than hammerite.

I've now refitted it and all looks rather nice!

 

Sadly and stupidly no before and after pics.

[Stolton 0]

Nice work mate.

[GLPoomobile 958]

Nice work mate.

 

Congratulations, you've spammed your way to your first 30 posts. So when's the For Sale thread going up?

[Simes 248 2 Cars]

Wow - I really have done very little to this car since April. Apart from a 2000 mile blast in the summer not much to report.

Collecting bits and pieces though for some interesting and exciting upgrades in the new year

[Miles 331 1 Cars]

A Turbo?

[Simes 248 2 Cars]

A Turbo?

 

Not quite.....although that's an idea!

 

Mainly collecting money so that I can sneak these upgrades in under the radar without anyone at home noticing.

[allye 530 3 Cars]

I was going to say supercharger but its a Mi! Look forward to this unfolding

[dcc 855]

I think somebody on here has a charged Mi, which made very good power and torque compared to the lynx kit on the gti6 engine.

[sensualt101 31 1 Cars]

all looking good! you are braver than i am i have to say to reshell a car!

[Simes 248 2 Cars]

all looking good! you are braver than i am i have to say to reshell a car!

 

I finished re-shelling it back in 2009

 

This is new stuff..........................

[sensualt101 31 1 Cars]

I finished re-shelling it back in 2009

 

This is new stuff..........................

 

yes i realised that simes lol! like i said all is looking good!

[Simes 248 2 Cars]

This arrived today (Thanks Tom)

 

and so did these

 

[allye 530 3 Cars]

Got mine last week Such a simple solution and really nicely made.

[Simes 248 2 Cars]

Today I got the car back in the garage for the first time since 2009!

I'll let the pictures do the talking

 

 

 

 

 

Finished! 2 1/2 hours for one side, 1 hour for the other!!



Next week
Lowering the radiator.

Edited December 20, 2012 by Simes

[Tom Fenton 1,542]

Tidy job, the way I've done them before is with a pair of holesaws to get the radiused ends then cut between to join them up.

[Simes 248 2 Cars]

Tidy job, the way I've done them before is with a pair of holesaws to get the radiused ends then cut between to join them up.

 

Thanks, I tidied them up a bit more following the picture and painted the bare metal.

 

I was going to use my hole punches and do the same as you but because of the reinforcement in the bonnet they wouldn't work.

 

Dremel blade and a lot of filing!!

[feb 47]

Next week

Lowering the radiator.

 

It's good to be able to have your own garage to work on cars.

Soon to come: bodies?

Edited January 29, 2012 by feb

[Simes 248 2 Cars]

-8 deg last night on our way home, for some reason I'd thought it might warm up later!

-6 deg C this morning
Waited for it to warm up a bit so once it got to -1 deg C I got to work. Left the car outside to work so that the sun kept me warm!!

Decided to to do a trial fit for lowering the radiator so that I could then work on recycling the old cowl and fan rather than spend more cash on a new SPAL fan.

Drained and removed the radiator

 

 

NEED TO ADD PICS!

 

 

 

 

 

Had to grind down the tow hook side of the new bracket so as to get to fit in

It's now in place but temporarily, car won't be used for a while.

This is a Nissen rad that I bought and have used since 2003 - it's twisted a bit but should be fine.



Next instalment

How to fit the fan to the rad
Making brackets for the grill
Treat the rust, tidy up the front end ready for some paint.

Edited December 20, 2012 by Simes

[allye 530 3 Cars]

How are you planning on securing the top of the rad? I doing the exact same thing at the moment with one of Tom's brackets and considering cutting down the twin fans instead of slim lines.

 

Will watch with interest!

[Simes 248 2 Cars]

How are you planning on securing the top of the rad? I doing the exact same thing at the moment with one of Tom's brackets and considering cutting down the twin fans instead of slim lines.

 

Will watch with interest!

 

Not sure yet, probably cable ties!!!

I've made enquiries about getting some mounting straps TIG welded to the top of the rad but not altogether sure.

 

I'm going to try as hard as I can to use the old cowling and fan. It was freezing out there today and my brain was not really working things out!!

I'd like to lower the fan more and that can only really be done buy tilting further forward.....which may mean buying a thinner fan.

 

Like this perhaps

 

Edited February 4, 2012 by Simes

[Simes 248 2 Cars]

I ended up buying a Revotec fan (11" sucking - on the advice of Revotec) and to cut out a bit of my rad to make the fan as efficient as possible

 

I attached some right angled aluminium to the radiator (I can't TIG - actually I can't weld) with bolts and rivets so I could then attach some builders type strapping. This extra material will also allow me to fit some ducting to it.

 

I'm probably going to revisit this again soon as I'd like to tidy it up better. However the radiator is solid, doesn't move and is plumbed in again.

 

Edited June 11, 2013 by Simes

[Simes 248 2 Cars]

Oh - this arrived today

I wonder what's in it

Thanks to Miles at Pug Racing.

[Simes 248 2 Cars]

I had an hour spare today and decided to remove the bits that are no longer required.

Bye bye GTI-6 inlet -

All gone, decided to bend the dipstick over due to manifold clearance issues.

Bits will be will be up for sale soon (EDIT 2013: sold)

Too tempting not to offer up the inlet. All ports match nicely which is a real bonus.

 

Ready for the cleaners!!

Back to work tomorrow - hopefully a few bits will arrive during the week for me to continue at the weekend.

[Tom Fenton 1,542]

If you can remove that top bracket and send it me, I can make it neater if you wish, probably by TIG welding some end brackets on it to mount to your chosen place rather than the wall tie. Let me know if this is of any interest?

 

 

PS- the easiest way to make the bracket fit is to "cough!" "adjust" the front panel "ears" it bolts to with the aid of a block of wood and a large hammer. The tolerances on 205 shells are such that the bracket is to narrow for some and too wide for others, but either way it is easy enough to massage the mounts to suit.