the.cern
Permanent resident
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« Reply #60 on: 13 July, 2011, 09:10:58 PM » |
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Well, today saw the rotisserie foibles sorted !!!!! I am now happy that we have satisfactorily dealt with the balance issue. The trick is to get the CoG of the shell level with the axis of rotation. If that can be achieved then, assuming the shell is symmetrical in the vertical plane, the only loads applied to the jig will be vertical loads directed through the points of rotation. Then the mechanism that locks the shell in position will carry only the live-loads that are applied whilst working on the shell, eg when pushing on the shell when grinding or wirebrushing. If it is not possible to align the CoG with the axis of rotation, then asymmetric loads are applied to the jig with one leg being loaded more than the other and the locking mechanism will carry dead-loads from the out-of-balance shell in addition to any normal live-loads. Rotating the shell will also require caution to ensure that it is always under control and will not suddenly flip over of its own accord. The problem to be overcome was that the CoG of the shell was too high relative to the axis of rotation. This was in part caused by the screens and the steering column still being on the shell. Simply removing them would improve the situation. The column came out easily enough (all the wiring was photographed and tagged) and the screens eventually succumbed (see separate thread). This alone was not enough and Jim fabricated brackets to increase the distance between the rotation axis and the points of attachment of the jig to the shell, in this case the bumper mountings. This has the effect of bringing the high CoG closer to the rotation axis. We did not know how much we would need to lower the shell, hence the multiple drilling of the drop arms !!!! To cut a long story short, it worked, the first photos show the shell at all angles whilst the last one shows one of the brackets Jim made to drop the shell. By chance we got it right first time, the drop is 125mm approx. It is now a one handed operation, with minimal effort, to flip the shell to any required angle where it may be locked in position. I wanted to ensure that it was possible to adjust the jig to provide this standard of operation before passing on the details. So, here are the details ........... They are available from 'mk2mania', a company that specialises in work on Mk2 Escorts, especially for the rally scene, web address, www.mk2mania.co.uk. The model is the 'de luxe rotator' and the price, a very reasonable £240 plus £40 delivery incl VAT. They will not provide the brackets to attach the shell to the jig, but these may be readily fabricated by a competent welder. Obviously the mounting points on the shell will need to be structurally sound !! I have no link with the company, but suggest that if you think it might help with work on your car, do have a look at their website, especially the youtube clip showing it in use and do check the caveat as to its use. Andy |
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DavidLaver
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« Reply #61 on: 13 July, 2011, 11:04:48 PM » |
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Having that level of access has anything else shown up on the shell?
Any creaks and groans as it spins or seems very much "of a piece"?
David
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David Laver, Lewisham.
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the.cern
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« Reply #62 on: 14 July, 2011, 06:16:08 AM » |
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David, I'm glad to report the only creaks and groans were from me, mainly due to age !!!!
Seriously, the whole shell is now very solid, but Jim has done a huge amount of work. I believe that serious consideration needs to be given to the condition of the shell before it is put on a jig like this. I would not have wanted to see mine on this before the sills and floor pan were done, but all the work on the rear spring hanger locations, around the lights, the front valance etc would have been so much easier if we'd had this. Maybe some would think that the sills could be done on the jig once the bracing in the door openings was in place, but I'm something of a coward when it comes to these things !!!!
Best wishes,
Andy
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the.cern
Permanent resident
Posts: 1494
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« Reply #63 on: 17 August, 2011, 08:53:33 PM » |
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Just a quick up-date on progress .......... the rotisserie is really proving its worth, both in terms of ease of access to parts that previously were almost impossible to access and also to check on work previously carried out. Jim is, to say the least, rigorous in the manner in which he works, but even he has found areas that were thought to be complete, but, literally, in the full light of day with the underside fully exposed, have found to needing a little more attention. I now understand how work that I have carried out on other cars and thought to be 100% has subsequently not lasted as would have been expected. It is simply that access is everything.
Well, there is now not a trace of underseal on the underside and the whole floor pan has been wire-brushed back to bare metal except for the nooks and crannies which I am tackling methodically with a variety of wire brushes in a small electric drill. An angle grinder with a wire brush is a very powerful tool, but rather cumbersome hence the smaller tools for those difficult to reach areas. When that is complete the two front wheel arches will need to be taken back to bare metal ............ all in all a huge amount of work, but something that cannot be rushed or skimped and needs to be done thoroughly. I think if I were to take on another project I would investigate the possibility of having the body blasted professionally and etch primed, as by Chugga and others
Yesterday the front section of the prop shaft was removed, complete with the bearing assembly. Today the pedal assembly was removed, degreased and cleaned in Gunk and generally fettled. Considering that it is located behind a protective cowl it really was in appalling condition, but now looks and operates like new.
Jim is generally tidying up the underside, finishing off bits and pieces that are now apparent, grinding welds back and etc before we get to the last major element, welding in the sills made by Bill Lewis, We know they are a perfect fit, the major work will come in 'blending them in' to the wheel arches.
Of course, as Jim delighted in telling me, I still have to take the interior of the floor back to bare metal ... but that won't be some time soon !!!!
More to follow as and when I am allowed to go out to play ............
Andy
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DavidLaver
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« Reply #64 on: 18 August, 2011, 10:26:17 PM » |
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The peddles must have been a treat after all the sheet metal.
David
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David Laver, Lewisham.
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the.cern
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Posts: 1494
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« Reply #65 on: 20 August, 2011, 07:45:13 AM » |
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You are absolutely right David. A real treat to get hold of something solid, covered in grease and with bits that moved and worked. I am much more at home with the mechanicals than the sheet metal bits. Fortunately Jim doesn't like getting greasy, but does enjoy beating hell out of flat sheet to make beautiful curves, something I am totally incapable of !!!
Andy
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DavidLaver
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« Reply #66 on: 22 August, 2011, 10:20:10 AM » |
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Doing all that wire brushing my tip is the best ear defenders you can find (these are the ones I got) and an IPod. I found regular defenders only let me listen to music (and I'd still go crazy...) while with these I can listen to speech and there's the world of fantastic podcasts out there. They've almost made that kind of chore a pleasure, for sure I want to keep going until whatever I'm listening to has ended rather than being desperate to quit for ANOTHER cuppa. http://www.handheldaudio.co.uk/pages/catalog.asp?divitype=t&tp_id=112&root_name=Hearing+Protection&pic=David |
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David Laver, Lewisham.
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Parisien
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« Reply #67 on: 08 November, 2011, 08:18:03 PM » |
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Andy, thank you, loved the read and slow embryonic-like development of your phoenix like B20!
PM in your inbox!
P
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Frank Gallagher
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the.cern
Permanent resident
Posts: 1494
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« Reply #68 on: 29 January, 2012, 09:12:05 PM » |
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Well, I've been very lax with keeping this thread up-to-date, but fortunately things have been progressing in the workshop even though they haven't been reported !!!
The shell is now structurally complete, fully welded and ready for the paint-shop, once the remainder of the paint, rust, underseal and general crud has been removed from the underside and from within the shell. Jim says all of that is my job, I cannot repeat what I said to Jim !!! Cleaning off the main areas is not too bad, the problem lies in cleaning up the areas which a wire wheel on the angle grinder cannot reach. I am hoping a spot blaster will do the trick, does anyone have any suggestions for a suitable blast medium please?
We have been pushing on with other bits, the de Dion had been stripped, the shock absorbers are in good condition and appear to function correctly so they will be left alone, at least for the moment!! The springs have been disassembled and I am 3/4 of the way through cleaning those, a ridiculously noisy and messy job!! So far I've used 4 wire wheels and blown up one angle grinder!! Jim is making new rivets and the tubular spacers for the brackets and, fortunately, both the special bolts holding the leaves together came out in re-usable condition. Hopefully they will be reassembled in the next couple of weeks, assuming I can obtain the interleaving.
We are now 4 days into refurbishing the left side door, it is fully stripped, a new double skin perforated stiffening member has been made, but there is still much to do, I left Jim repairing the diagonal tubular braces.
One thing that has pleased me through this part of the work is the discovery of build numbers stamped on the various elements of the body. The boot floor has 14625 stamped on it whilst both doors, the bootlid and the bonnet has 625 stamped on them. It would appear that the car has all the original matching elements and, as there was no sign of accident damage to the shell, it seems the car has never been involved in an accident!! I was surprised, until I thought about the amount of use it has had. The first 8 years in Italy presumably totted up some mileage, the next 7 years in the UK might well have seen reasonable use, but the next owner, from whom I bought the car, I know did few miles, as did I, until its incarceration in the mid seventies. At this point I decided to check the odometer, just over 51000km !!! Bearing in mind the above analysis, this could be correct. I hope the engine rebuild will be able to confirm this.
So, that's where we are at the moment, more will follow, hopefully with photographs. I really must decide on a colour, soon!!
Andy
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Parisien
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« Reply #69 on: 29 January, 2012, 09:16:58 PM » |
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Great to hear of the steady progress Andy and no other surprises.
Keep up the good work and looking forward to the pics.
P
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Frank Gallagher
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DavidLaver
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« Reply #70 on: 29 January, 2012, 09:17:49 PM » |
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Great to hear of the progress.
My vote is still black - a colour I never OTHERWISE like on a car.
David
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David Laver, Lewisham.
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Parisien
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« Reply #71 on: 29 January, 2012, 09:27:35 PM » |
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Great to hear of the progress.
My vote is still black - a colour I never OTHERWISE like on a car.
David
Looks fab in black too......but some of the pastels are gorgeous too..... P |
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Frank Gallagher
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DavidLaver
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« Reply #72 on: 03 February, 2012, 06:11:36 PM » |
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David Laver, Lewisham.
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rogerelias
Rebel Poster
Posts: 955
MY 1600HF IN HEARTBEAT GARAGE
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« Reply #74 on: 19 February, 2012, 10:39:26 PM » |
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DROOL DROOL  |
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FULVIA 1600HF LUSSO
1958 VELOCETTE MAC
Triumph Bonneville t120v 1972
1968 MGC ROADSTER
1958 Series 2 Appia berlina
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