4.2 Bodyoff Rebuild

4.2 Bodyoff Rebuild

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scerbera

Original Poster:

85 posts

106 months

Monday 3rd October 2016
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Hello to anyone reading.

I've decided to do a body off on my Cerbera, it's a 96 4.2. I'm going to use this thread to keep a diary, ask questions, upload pics e.t.c

I managed to get the cerb in my new unit yesterday, bit of a pain as to get in you have to negotiate a 700mm concrete loading bay step. So a ramp was made out of scaffolding. I have no lift at the moment and may get one installed but it's not an immediate priority. The car is on a mini ramp right now with just enough room to get under.

Progress so far I only had 2 hours on it, I occasionally will have my brother available to help with the odd thing.

Bonnet off, exhaust up to and including cats.
Helmet holder.
Prop shaft.
Gear lever.
Struggling with handbrake as pin is in the wrong way, pic to follow tomorrow, forgot today.
Rad is drained.

I am going to grind every bolt straight off I don't have time or inclination to mess about. Some pics below.







ukkid35

6,136 posts

172 months

Monday 3rd October 2016
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scerbera said:
I am going to grind every bolt straight off I don't have time or inclination to mess about. Some pics below.
I'm not convinced that's necessary. If it doesn't come straight off chances are it will sheer, saving you a lot of grinding time (or not depending).

However any sort of pneumatic or electric gun will help a lot. I've only had the chance to use a Clarke CEW1000 when dismantling, and it does make a massive difference.

domhonmong

18 posts

91 months

Tuesday 4th October 2016
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Keeping a keen eye on this thread smile

stickylabels

519 posts

91 months

Tuesday 4th October 2016
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Me too!

stickylabels

scerbera

Original Poster:

85 posts

106 months

Tuesday 4th October 2016
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Another 90 mins on this today, I'll try to be accurate with my timekeeping so we can see total hours at the end. I'll take a few more pics tomorrow, I had to rush off. I'm going to try to be as detailed as I can so that I have a reference in putting this thing back together.

Today I undid most of the chassis bolts that you can see from bottom and top of the floor pan. They came off easily enough. You have to pull the carpet up to access. I am not taking care of the carpet its all being binned! The rear seat bolsters just pull off with velcro and in my case glue. The rear seat underleg bolster also just pulls off. Some of the foam was left behind. The rear panels that have the seat belt running through them also just pull out, there is one wingnut up at the top which I'm guessing you should undo but I didn't need to it slid out easy enough. I think that there is possibly scope for a bit more rear passenger room in reducing thickness of rear of seats, just a little. I was surprised how pulling the bolster off would allow a carseat to sit back at least 50mm more which makes a massive difference on the drivers side. I'll be investigating this more.

I have taken the seatbelt reels out, which you need to do in order to get a spanner on the 17mm nut and bolt behind. Front carpets are mostly out then I cut them where the seat holds. Pics below of the order the seatbelt fixing construction. 5/8 imperial for the seatbelt bolts, and floor bolt. The assembly of this I think could be improved aesthetically, I may machine up something in alloy time permitting.

i am going to put everything into labelled tubs which I need to start doing tomorrow if I get a chance.

Everything that has come off so far has been simple. I am feeling optimistic that I can get the car trimmed for a reasonable price. Everything so far could be done fairly easily. I have horrible faded cream on black, with biscuit colour carpet. Floor carpet is red.

The biscuit and cream besides being old and water stained looks crap. The biscuit carpet especially is gross!

I'm not sure what colour I'm going to go for. I think maybe black and red, or white and red, if black then possibly anthracite wheels to match. The wood veneer on dash is well past it's best days also so something will be done to that.

A bolt I am unable to do at the moment is any seat runner, or the bolt which goes into outrigger that holds on the seatbelt slide rail. It just turns but I cant see how it cant just be straight into outrigger. If anyone knows then let me know before I grind it off and have to make a new rail.



Tanguero

4,535 posts

200 months

Tuesday 4th October 2016
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The bolt goes into a threaded hole in a tab on the outrigger, if its just turning then it has probably stripped the thread. The seatbelt rail is hardened and very tough, you will have to replace it with a new one if you cut it. Any old bit of steel will not do!

Edited by Tanguero on Tuesday 4th October 22:14

ianwhitewick

137 posts

170 months

Tuesday 4th October 2016
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Take photos of everything. You can't take too many. Chinese takeaway boxes are a good idea too and an excuse for a Chinese! Label everything too.

I replaced all the bolts on mine. The sticky at the top of the forum was correct for 98% of my bolts.

Good luck!

scerbera

Original Poster:

85 posts

106 months

Tuesday 4th October 2016
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Many thanks, I will work something out for that bolt.

Yes I will take more pics! Thanks.

Poopdog

163 posts

91 months

Wednesday 28th December 2016
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Any updates?

scerbera

Original Poster:

85 posts

106 months

Thursday 29th December 2016
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Poopdog said:
Any updates?
Hi thanks for asking,

Not too much at the moment, I haven't got the body off yet, but i'll be putting in some hours later today. I have been very busy and not had time, the car is still on ramps, I have fuel tank disconnected, boot off, rads, battery, seats out.

I am maybe 4/5 hours away from getting the body off, at which point progress will be much swifter as it will be smaller jobs I can do when I only have a few minutes spare.

The task I am a little stuck on is getting my dash structure off, so the whole front from passenger side to driver, I have removed all the bolts, but it appears that the whole thing is glued on, and it is solid. Has anyone else come across this before I wonder?

greenracing

259 posts

170 months

Friday 30th December 2016
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The dash is in two parts. The upper part can stay put and the lower part is fixed to the upper part using self tapping screws, think there are 4 from memory. I assume that you have removed the 4 bolts (2 from either side) already .....

I took off the binnacle and the 2 screws holding in the speed/tacho panel as you need to turn this and pass it through the dash as you take it out of the car.

Hope this makes sense.

greenracing

259 posts

170 months

Friday 30th December 2016
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Image of screws.

scerbera

Original Poster:

85 posts

106 months

Friday 30th December 2016
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scerbera

Original Poster:

85 posts

106 months

Friday 30th December 2016
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scerbera

Original Poster:

85 posts

106 months

Friday 30th December 2016
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scerbera

Original Poster:

85 posts

106 months

Friday 30th December 2016
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scerbera

Original Poster:

85 posts

106 months

Friday 30th December 2016
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scerbera

Original Poster:

85 posts

106 months

Friday 30th December 2016
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scerbera

Original Poster:

85 posts

106 months

Friday 30th December 2016
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scerbera

Original Poster:

85 posts

106 months

Friday 30th December 2016
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