2024/02/15 13:29:28
deano
thanks for the suggestion, might be good for some inspiration like you say.
I'm reluctant to go full show car spec, the van was always planned to be a low budget setup, at least for the first iteration.
As an aside, about 8 years ago I installed a temp sensor and elcheapish Ebay temp guage (KUS, under $50) into the outboard on the boat. It was handy to know its still pumping water, as you cant see it tucked away.
Its still goign strong, depsite being in the weather, as looks abit classic style.
 
Best bit, they have a BS guage also, so you can tell if there's too much Sh*t  going on: 

 
 
 
 

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2024/02/18 19:14:44
MarkA
I have put KUS gauges in the boat. They look much like the ones you have posted there Deano.
They came on good recommendation so time will tell.
GPS speedo is the only thing not old school.

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2024/02/27 13:22:31
deano
so a bit more progress.
I forget how little can get done sometimes when it comes to bodywork.
The drivers side wheeltub was again done in 2 sections, I found it was easier to manage when it didn't take up the whole infil, plus it made it a little easier to see how close the fitting was, and to be able to get the clamps in.
 
Inside the van also, is the stiffener brace that connects down to the inner tub and arch sidewall to take the roof load. This was a pain in the butt, just like the other side was actually, and needed some mods to cope with the raised tub.
That still needs some decent rewelding to ensure it is as strong as previous.

It probably would have been easier to do this job on the spit as well, next time.

Again, not very exciting job, and a bit fiddly.
I tried to be smart and make a new template out of cardboard strips, and pinched the kids hot glue gun.
That should have come with a warning,about the glue when it drips between the cardboard while you hold it in situ, and it dollops out onto your thumb, and continues to cook for 5 minutes before cooling.
 
Found some rust (maybe the final?) in the floor, which I think will extend more than it looks currently.

 
Marty looks to have the dash clock pod just about all sewn up, so pressure is on to finish making a grinding and sanding mess inside the van, so the dash fascia can be sanded and painted again in readyness.
 
And finally, I'm not sure if under the arches should be 'Raptored' black, or finished in body colour?
I reckon the van will finish sitting high, or at least i'm not aiming for a low look at all with this, so it means alot of the area under the guards will be visible. Body colour looks 'new' and fresh, but it will probably go manky in time, and generally look more of a mess, so not sure.

 

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2024/02/29 19:18:52
MarkA
Deano, Looking closer. I reckon putting some paint on a finished body makes it all worthwhile.
 
Is that 'De Lorean' pic of the floor at the rear doors?
2024/02/29 19:57:44
escortinadriver
Getting there!

Yep, body work always seems to take for ever.
2024/03/08 13:18:02
deano
so a little bit more done.
Inside the arch painted, will do some seam sealer when all of the seams are done together

and since the paint was out, I started on painting bits inside the van that you wont see once its upholstered

made the patch piece up for the floor with the folder:
 
 

 
and welded in place:.... but I wont show that, it wasnt my best effort. In hindsight, doing a Fizty butt join wasnt the ideal way to go. It welded fine for 90%, but in some areas it was thin, a better method would have been to joggle a return to tuck under the floor, and then plug weld through and seam weld in spots.
Its still way better than before, but hey ho, you live and learn.
 
 
 

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2024/03/08 13:22:26
deano
one thing I did find, was this $7 stool from Kmart.
I was going to weld something up low to sit on, but found this plastic folding stool.
You do need to have a pettite butt like mine, but its light and easy to grab with a welding glove on, and usually stays where you left it when you are up and down with your head bent under the wheelarch.
Bets of all, it folds up and can hang anywhere.

 
 

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2024/05/13 13:35:55
deano
well you know thats its been awhile between updating when you can't even find your build thread!
 
But things should return to normal shortly, as the Rally Pack has now all but gone to a good home, thankfully only a few hundred kms away, and to a nice bloke as well. Its had the last wash and clean, thats it, no more driving it.
 
Boy, getting a roadworthy these days is an absolute pain in the buttocks.
It took over 4 weeks, and 2 testers, who each had their own interpretation of RWC hoops needed to jump through.
And a massive thanks to Part Time Mk2, who lent me an otherwise unsourceable air clear with intake valve.
I did learn how to replace a 2 piece tailshaft centre coupling, gearbox extension housing seal, and also fabricate a handbrake lever warning switch and loom, so not wasted.
 
Anyhow, its done now.
The 'delorean floor' in the back of the van is fixed, and the repaired area is just about ready to paint.
As a bonus, I found in a box in the cupboard a complete tacho dash, which now sports LED lights and arefreshed pointers. 

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2024/05/13 15:21:42
escortinadriver
If you don't mind me asking, what was the trouble with the RWC issue?

I'll be heading down this road near enough.

Thanks, Shaun.
2024/05/13 18:22:26
deano
no worries Shaun.
Well, lots to start with. To be fair, the first inspection was basically to just find whatever still needed sorting, and I expected to have a list of items to 'finish off'. As the car was effectively a reassembly/part resto, much like your Cortina, it was the start of the shakedown if you like. So what they identified as 'defect''s, apart from some suspension bushes, centre tailshaft bearing, indicators not self cancelling, flasher intermittently going fast, drivers door seal, the biggest issue he saw was the parcel shelf had larger speakers fitted. This is apparently a no-no in his eyes. Oh, and the car had a ghia handbrake warning light, but no sensor switch to activate it. Other things, AGR system was 90% complete, with the charchoal filter as opposed to catch can,all of the anti pollution hoses, but he wanted the air intake flapper there, and there was no 'heater inlet pipe' that goes from the exhaust manifold to the AGR valve. This had been altered at some stage as the car had extractors, and thus no connection.
So Mark lent me his fully kitted air filter,, I made a handbrake switch and loom, plumbed up the heat tube, shifted the steering wheel indicator column to cancel correctly, and restored the parcel shelf to factory, welding in steel panels.
To continue, if you want all of the gory details, at second inspection he looked at the steelwork repairs and did not believe they were welded in (and seamsealed, and epoxy primed etc) despite having document photos, so he was a knob basically. I went to another tester, who reran a full check on the items, added his own list of defects, loose seat frame, one headlight too high, and slight weep from gearbox housing. Pay more money to get extra items fixed and then its cleaned and  tested and passes.
Unfortunately, my experience is that RWC at least in Vic, is a flexible guide only, open to interpretation by the inspectors. They all have their kwerks of what they want to defect. eg Second inspector said the rear demister isn't a requirement, you only need windscreen demisting. Given this car really looked antipollution compliant, with hoses going everywhere, I don't know how the van will go when the time comes, as it will only likely have a catch can. Much of the AP vacuum gear isnt around anymore.
It might force the move to the bike ITB and Speediuno as the fuel injection is alot more controllable than the weber 32/36.
My tips for next time, obviously make sure the car is spotless underneath, expect every bush,boot,seal and rubber will have to be replaced, and basically just expect to get caught out by at least a few items you never considered. Then, just get a quote on having them repair the items, dont do it yourself. I worked through the 20 'defects' and fixed every one, only to have a not nice person say it was unacceptable. Just pay them to fix it. If they wipe a rag over it, add some cable ties, whatever, so long as they say its up to scratch, then thats what you need.
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