Thanks for the progress updates. The garage looks like a good place to be, always half the fight keeping it clean and organized.
Bummer to hear about the engine but on the upside you'll have some piece of mind when its all put back together properly.
For things like the diff housing, springs etc have you thought about powdercoating? I do it with all my stuff nowadays, cost and time wise it works out cheaper in the long run and its as tough as boots.
The KBS stuff is good but I've had it flake off in sheets on a couple of bits, they really need to develop a primer to go with it IMO. 

Hi Guys, funny you mention the KBS rust seal and blacktop.
I have trouble getting a good a good finish in the warmer weather so probably should look at getting some of their thinner?
On bits under the car I don't fuss too much but I'll be interested to know how the diff comes up if you do scuff it up and re-coat it Mark. It certainly looks okay in your photo. Better than mine done with rust seal
 
I have only had one thing bubble on me once (fuel tank) and I know it was thoroughly clean. I just cut out the section which was bubbling (about 50x50mm) cleaned it, re-coated and never had another issue.

I am going to get the fuel tank dipped and powder coated - same with all the smaller parts. I decided to just give it a crack considering KBS had some good reviews and the diff seemed like the part to give it a shot on. If I can't get it as smooth as I want I may bite the bullet and strip it again and get it powder coated. 

I'll be giving it a test rub in the morning so i'll post an update tomorrow arvo if it works out. Nothing ventured nothing gained. 

At the end of the day though its under the car and already looks 100x better than it did . Eventually i'll need to make up new brake hard lines and brackets when I get the rear calipers etc too so if the KBS turns out good with this I can use it on all the little one off brackets that I make up.

^^ that Minisport website was a bit of a good find.
Having someone in Aus selling JBW's is a bonus.
I'm happy with their minilight repro that I got for the 4 door.
 
They were pretty safe 13x6, but had to be bought from Race and Rally in the UK, as no Aus dealers at the time.
Your Minisport mob would have worked out cheaper.
I think you are way on track for a 2 year turnaround.
 
And 2 month is looking quite possible also...:)
 
 
 

Hahaha I'm back at work next week so things will slow down once that happens. Plus the in-laws are coming over from England in Feb for a month so there wont be much car time over the next little while. Hence why I'm trying to get stuff done now!

NurseBetty accross on oldschoolford has awesome wheel fitment on their car - standard arches, looks really really sharp and they're 15s.... too many choices!

Ok I think I've cracked the KBS code - I sanded the whole thing back with 600 grit wed and dry, dried it off, cleaned it then used a new 5mm microfiber mini roller that's been washed in thinners and dried out.
 
Use the edge of the roller to get in the nooks and crannies then smooth it out and back roll - just like painting a wall. Came up really well and that's just one coat, I'm going to let it cure for a while, nock the nibs/dust off with some 1200 then do one final coat.

That casing looks too good to be disappeared under a car 👍.
I did paint the casing on the yellow lugger van in 2pk sniper black, a Focus colour and all the hard effort vanished when it's bolted up and hidden...

I know right . It's a sickness.


Last coat on - now ill let it dry then hit it with a light cutting compound in a few weeks for science. 

So the process applying the KBS from start to finish.
 
1. Full bare metal rub down, used wire wheel and stripping wheel on the grinder.
2. Cleaned with thinners then used a blowtorch to burn off any remaining residue.
3. Two coats brushed on, wasn't happy with finish so rubbed it back with 600 until smooth then cleaned with water then fully dried.
4. Applied one coat with 5mm microfiber mini roller, back rolled over it. The product is VERY forgiving, it has a long open time, I went back to the start to touch parts up after about 3 minutes and it still leveled out nice.
5. Allowed to dry for twoish hours until touch dry then gave it a VERY light rub with 1200 to knock the dust and a few other bits of crap off the surface.
6. Applied last coat same as step 4.
 

 
It's not perfect but I'm a lot happier with it now - I don't think I could have left it the way it was. Once it's had a light buff I think it'll come up even better. The diff casing will be painted matt silver which I think will make it pop quite nicely, Ill get the tramp rods and leaf spring brackets/shock mount powder coated matt silver too. 
  
 

are you sure your happy with the finish? :)
Definitely wasted unless you can include some stick on mirrors around so we can see the efforts of that hard graft.
 
I think the majority of posters here have a sickness as you mentioned.
For some its polishing shiny bits to within an inch of its life.
Mine is always doing things twice, and not listening to those who give good advise in the first place.
 
With the rello''s coming out, have you though about paying for some extra carry on, and asking them to swing past Burtons on the way over? 
 

You only know it's done right when you do it wrong first !

I did consider it! I'm headed back there for Christmas this year I think, the partner wants to spend it with her parents this year. By then I should be far enough along that I'll have a "definitive" list of what I'll need and organize it while I'm there because postage stacks up so fast. 

A pallet can be organized for a reasonable price but sea freight takes ages. I am going to try my best to source everything locally but there's just so much on offer there that you cant get here.