MX5 Berkeley to MEV Exocet projec

MX5 Berkeley to MEV Exocet projec

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browno

Original Poster:

508 posts

234 months

Saturday 10th September 2016
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Well, progress has slowed somewhat here due to holidays and more jobs to be done on the house over the summer, and as a result there isn't too much to report - but I have at least managed to get into the garage and fire up the grinder briefly to see what is facing me inside the passenger rear quarter panel - where the area around the arch lip was beginning to bubble and had gone through in one area.



so with a bit of chopping out, we can see what is going on inside (and also find that the lower lip of the inner arch came away with the outer skin, so that will need replacing)...



and we can also see the repairs that were conducted to the inner sill area 3 or so years ago - but that there is some corrosion further up on the inside that needs cleaning pack and treating.



I also needed to do some a service on my wife's clio 182, so the green one saw the outside world for a couple of hours alongside my mk3...





so, now that the summer break is over, I am hoping (travel permitting!) to be able to spend some time in the garage and get the rest of the areas that need patching all chopped out and cleaned up, and then prepare the repair panels ready to get them welded up... although in the meantime I need to also service the mk3 and fit new discs and pads ready to try and squeeze in a trackday or two before the end of the year!

Edited by browno on Saturday 10th September 22:11

browno

Original Poster:

508 posts

234 months

Thursday 29th September 2016
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Another mini-update as I have managed to at least get into the garage briefly to do a little more choppingl Afraid to say that I haven't made loads of progress, but I am seeing a little more of what I am facing...

So first I chopped a little lower on the bottom of the sill - revealing quite a bit of rust in the area that has been previously repaired... due to the corrosion on the inner edge too, the lower lip also fell away with the outer skin.





A bit of an attack with the flap wheel does make it look much better - with much of the issue here looking like surface rust.



So I put a coat of rust converter on to try and improve things, but looking from below, we can really see the problem. There is still some more work to do to remove the rust and see what is needed to start repairing the damage - I think and inner sill repair, fabricate the inner/underside panel that forms the bottom edge, and look at how much of the sill closure panel needs chopping away to see whether that can be patched or if I need a replacement panel.



So I don't think I will be driving it to the OC national rally on Sunday, but I am at least slowly moving forwards. Having had another busy few weeks I am hoping that things are starting to quieten down a little so that I can make a bit more progress soon!

browno

Original Poster:

508 posts

234 months

Monday 3rd October 2016
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A bit more chopping done tonight to get rid of some more of the rot - but opening up some holes!

Firstly under the o/s inner sill, which as had a 1/4 panel and looks ok beyond this patch (obviously, I need to do a bit more chopping and continue cleaning back to protect everything once it is welded up).



And similar area on the n/s which is rather more in need!





And clearing the holes out of the sill closing panel/inner wheelarch area



The same are from inside the wheelarch



Then finally the area on the n/s front lower wing mounting, which needs a small patch.



Then finally a slightly superfluous job, given the state of the rest of the car - I removed the front plate and plinth...



I have ordered the inner will panel to replace the n/s and give me a lower lip to work with - and should allow me to fabricate the panel for the underside of the inner. So it is looking pretty serious, but at least I am starting to be able to see what needs to be done...

browno

Original Poster:

508 posts

234 months

Saturday 5th November 2016
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Time for another update on a bit more progress...

Some more chopping and cleaning up the inner wheelarch.



And some more chopping away the lower inner sill for the repair panel.





Back panel removed (and also the bumper, but haven't taken a pic of that)



So, having raided the scrap bin at work for some sheet offcuts to try welding, I got impatient and began making a start at fabricating the patches starting with the little ones - front of the sill first.



Then the holes in the wheelarch:





So we are heading a small step in the right direction - and I hope to be able to begin reconstruction shortly (well, maybe just a bit more chopping!)

S6OOH

1,068 posts

257 months

Sunday 6th November 2016
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Good work OP

Roy Lime

594 posts

132 months

Sunday 6th November 2016
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Well this one brings back memories; I had one of these in 1998. Just checked and it's showing as having an MOT. Someone, somewhere still loves it. Good.

browno

Original Poster:

508 posts

234 months

Monday 7th November 2016
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Cheers Guys - and good to hear yours is still on the road Roy!

I am conscious that I am probably making a proper meal of something that would likely take a pro a day or two, but I hope my amateur ramblings are at least of interest!

Today was having a go at a bit more metal bashing - with the lower sections of the inner sill to do - which were a little trickier! So first job was to raid the recycling bin for some cereal boxes to make templates!



And then after a fair bit of trial and error (and some duct tape in place of weld for now...) we have some more patches (all patches have been made from sheet that is a bit chunkier than the original steel to try and both give some meat to weld to but also maximise strength of the repairs).



Which still need a little tweaking but should eventually marry up to the lower sill repair I bought to sort that area out...



So we are beginning on the road back to repair - just a few more bits to make and then the small matter of getting it all stuck together left to go!

darkyoung1000

2,028 posts

196 months

Tuesday 8th November 2016
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I've thoroughly enjoyed reading this OP, please keep the updates coming. Nice to see welding skills being learnt in the pursuit of saving another Mk1.
Definitely my favourite of the MX5s, a friend had one for a couple of years, and my Mother has a low mileage R reg one in tidy condition!

Cheers,
Tom

browno

Original Poster:

508 posts

234 months

Wednesday 30th November 2016
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Thanks for the comments Tom - although today's update has no progress of any note to report (has been another crazy few weeks), and I am having a crisis of confidence in what to do next...

I am having thoughts as to whether I should continue fixing it up, and leave it as what will be a tidy, but possibly not exceptional mk1 (depending on how much I want to commit to spending on it, of course!) - which I am not sure is something that I will keep long-term, unless I end up with it looking truly excellent, or whether to revert to plan A and use it as the basis for a mechanically sorted Exocet. I keep flipping between options, especially as I haven't made much progress for a while, and want to keep it moving. The big hurdle currently being that I need to get hold of a welder and teach myself to weld, or get it all done for me (which is likely to be a significant cost)...

I think a key thing will be to get my mate (mechanic who owns a local garage) to have a good dispassionate look over it and see what he reckons is possible with it before I either continue fixing or start ripping it to bits! That way, I will have a decent idea of whether it is worth digging a little more and getting rid of absolutely all the rust in the car, leaving it structurally good, or if it is likely to be just as bad again after a couple of years, even if I fix what I can see now... that is then likely to be the key to deciding where I go next - and of course the views of the assembled masses!

Phil SW

9 posts

125 months

Thursday 1st December 2016
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Thanks for the write-up browno, it's interesting to read for those of us without the spare space/time to do something similar ourselves, but hopefully some day! it seems that since you've gone this far it would be a shame not to finish it off? Maybe use this one as a learning experience, sell it on ad buy one of the many worse ones out there for the kit car?

I can't weld, but one thing I have learnt from my previous battles with rust - you have to get every last bit of it or it will soon be back. Rust converter isn't as good as going back to clean metal. Maybe once the patches are on get the areas media blasted before paint?

browno

Original Poster:

508 posts

234 months

Tuesday 3rd January 2017
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Time for an update - So having got to his stage, as mentioned before, I have taken stock of what needs doing, and with large holes in the rear inner sills, one quarter panel and holes to the from of one inner sill and one frame rail to sort I have come to the conclusion that while it might be possible to fix all of that, I am still going to be left with a relatively average car - without throwing loads of cash at it to do a complete rebuild and respray - and I think that treatment might be best reserved for early and/or very special cars at the moment.

As a result of this, I think it is time to stop being sentimental and get back to plan A - turn it into something unusual and fun! My thoughts are still going with an exocet to provide something that isn't yet another seven-type car (not saying there is anything wrong with them, but I think with a seven I would want a caterham, even though the roadrunner does look like a very good kit) and is more unusual - along with it keeping much more of the Mazda parts and nature, and potentially being an easier build for my first kit car.

I haven't done anything really to the mazda over christmas, other than switch the cars round in the garage so I have better access to my mini and can get it on the lift. My plan right now is to put the Mazda on hold for a little while until I can get my mini (a 23-year project that needs finishing!) all sorted and MOTd and then rip into taking the mazda to bits.


The mini taken around 3 years ago before I built my new garage (looking the same as it does today!)

I have robbed the mazda of its front indicator bulb holders - I had a short on the indicators on the mini from within the front indicator units (dodgy fittings in there, allowing the connectors to short), so I looked up and saw the fittings on the mazda would fit, and so a quick wire cut and splice later, then it made its first parts donation! I am now waiting on new indicator and hazard relays to arrive, as the short appears to have fried them, then it is on with more of the list of jobs pre-MOT. I don't think there is a lot to do really - it starts and stops ok (but does need setting up properly), I need to refit the grille and bonnet properly and make the interior look presentable, and then I think it will be time to get it in and see what it needs for its first MOT since August 1993!

As I said above the plan is to get the mini MOT'd before really ripping into the mazda - but I am planning on getting started photographing and listing some bits for sale soon to get bits out of the way, and to go towards the cost of the kit! If anyone needs anything body/interior wise, then let me know - I know there are a few Berkeley owners on here, and I would be quite pleased if I can help to preserve some of the other Berkeleys with parts from this one!

browno

Original Poster:

508 posts

234 months

Monday 27th February 2017
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So it has been a while but it is time to resurrect this thread from its slumber...

I have managed to get my mini sorted and ready for MOT (it failed, but is being sorted!), so I am now back on sorting this one...

Firstly I have started stripping and selling off some parts, so far getting rid of the hardtop, boot lid, bumpers, mirrors, brace bar and tonneau, which is a good start on my aim to recover the cost of the donor in parts sales.

With those bits off and a few more starting to be stripped, the car is looking a bit more bare:

09B32713-4560-47BC-9C14-D69BF15BC266_zps50cxfeux on Flickr

and the boot is filling up with trim that is coming off...

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and tonight I have begun removing the dash - making sure to label all wiring! The dash is now free but needs the column lowering a little to make sure it will come out...

ABE8D134-AA02-4CC4-85EE-050630587836_zpsfxx8xdf7 on Flickr

So just a bit of progress, but it is good to see it start to come apart - although I need to keep the momentum at selling parts as I fear the car will take up rather more space in bits (if anyone needs. anything, let me know, or see my parts sale thread)! My overall plan from here is to get the car stripped and get rid of everything I don't need then start to work on cleaning and refurbing the mechanical bits before ordering the kit - I will then have the duration of the order lead time to get everything cleaned sorted and rebuilt before the kit arrives for building.

Edited by browno on Tuesday 15th August 22:02

TooMany2cvs

29,008 posts

126 months

Tuesday 28th February 2017
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Galling though I'm sure it is, after the time and effort you've put in to repairing the shell so far, I think you're making the right decision. There's still plenty of decent MX5s out there, and one that's been patched-up will never repay the work and money put into it.

browno

Original Poster:

508 posts

234 months

Thursday 2nd March 2017
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TooMany2cvs said:
Galling though I'm sure it is, after the time and effort you've put in to repairing the shell so far, I think you're making the right decision. There's still plenty of decent MX5s out there, and one that's been patched-up will never repay the work and money put into it.
Thanks - that is really my thinking, there are plenty of other cars out there, and I want something that I will enjoy at the end of it, so I think this is the right way to go.

So, a little more progress tonight on the stripdown - after a lot of fiddly fixings I have managed to get both doors off and also (after the fiddly job of extracting the dash loom) removed the dash - while making sure that all connectors are labelled and that I remembered to remove the immobiliser module from below the dash.
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which means that the back of the car is getting increasingly covered in parts to sell off

49FB8872-AA84-49F6-BEF3-1383A0AA95AC_zpschgbr6er on Flickr

Although progress on that front is continuing - so while I am taking this car to bits, it is at least helping others to live on - including parts like the original stereo that was one of the limited edition features that is being passed on restore originality to another Berkeley...

735E35F0-30BE-4767-9433-FC09004F93A0_zps8pkq5h1q on Flickr

Edited by browno on Tuesday 15th August 22:11

browno

Original Poster:

508 posts

234 months

Monday 20th March 2017
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So, time for another update on what is happening with this - I have slowed progress on this somewhat as I have been busy on my other project - which is a 1985 mini that I bought back in 1993 to tidy up as my first car... and which I have finally got MOTd on Saturday after a full rebuild (and 23 1/2 years!).

I have got some more done to the deconstruction of the green one though, and am going to visit MEV on Friday to check that the Exocet is the right kit for me (I am still pondering the seven-type kits as a backup, but given the cost to build one of them I may as well go out and buy a decent ready to run westfield...).

So after the last update, the next job was to whip out the seats and carpets, which (with some help from my 7-yr old son!) was easily achieved.

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which left me with a car piled with bits

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Then I removed the headlights and started clearing under bonnet wiring - with the n/s being relatively easy to access and sort, before pushing it all through the bulkhead, while making a good start at labelling the o/s. One note here is that I have been using a label printer that I picked up from costco ages ago (the machine is only about £7-8, tapes aren't cheap, but not horrid at about £20 for 6 from Amazon) which has made ensuring that I have labels that will stick to the wires and remain legible very simple - and hopefulyl durable too.

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which left the cabin filled with more wiring

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Since that I have drained the coolant so that I could remove the heater matrix and free the harness behind it, and label and free all the wiring on the o/s - apart from one section that runs under the brake servo and doesn't want to come out - so tonights job is to remove the servo and master cylinder to allow me to remove the last of the wiring completely. For now, the interior is looking rather more bare than it was!

8E68F7E7-292E-4685-AEA6-C8A3DD591EEA_zpslv53cmxk on Flickr

I have to say that as I go through this, and compare to the mini that it is interesting to see the differences in design and build methods - the mini had clearly evolved by trial and error, whereas the mazda is very much designed, and everything planned and executed for reliability, but also for ease of manufacture (and service to a degree).

Edited by browno on Tuesday 15th August 22:20

browno

Original Poster:

508 posts

234 months

Tuesday 4th April 2017
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A mini-update for today, but with a couple of important steps achieved (but a failure to take any new pictures!)!

Firstly, to get ready for the next steps I had a ride over to MEV in Mansfield to meet Julie and Stuart to have a good look over an exocet in the metal (I had had a look at Stoneleigh last year, but at that point was erring towards a restoration!), and more importantly think about options and colours that might work. It was great to spend some time looking over the cars and chassis and get Julie and Stuart's experiences of many different builds.

I had thought of a colour scheme (that I hadn't seen done before), but then having played with photoshop was not convinced by it. I have then been playing around a little more and have a final plan (again a combination that haven't seen) - and after a bit of confirmation with Stuart that it will work, my order is now in - pending confirmation of any very final changes once I have seen the new demo car at Stoneleigh... This should then give me plenty of time to get the body off and everything tidied up before collection day! My plan at this stage being that I want the build to be quicker than the mini... quite a lot quicker in fact, and would like to be on the road by next spring - let's wait and see!

As a result of that, I have been getting the last bits stripped from the donor,so since the last update, I have removed the loom, steering column, handbrake cable, brake lines and fuel pipes and am almost ready to lift the body. One good piece of news is that I stuck it on my lift yesterday and removed a few of the subframe bolts and they all look to be ok to remove with my impact gun - so that's another worry off my mind. Following that, I put in my wooden props in each corner and started removing bolts - it is currently sat with all but 2 subframe bolts out ready for the body to come off later this week.

I have also now provisionally the interior from the donor, so that's a little more into the pot for shiny bits!

Finally, (and slightly prematurely!) I a reasonably priced set of new pro-race 1.2 wheels on ebay, so I snapped them up - 15x7 et25 in matt black - which will suit my colour scheme perfectly. I am a fan of the pro race wheels, having had a set of anthracite 18's on my old Vectra VXR, and I think the style and light weight of them will suit the Exocet well...

anonymous-user

54 months

Tuesday 4th April 2017
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It's sad that som many "limited edition" models (and the normal mk1 MX5 anyway) were scrapped in the scrappage scheme.
Someone scrapped a Delta Integrale.. and a 3-4 year old BMW X3 3 litre !!

mx-6

5,983 posts

213 months

Tuesday 4th April 2017
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Great work on the '5, will look forward to seeing how it comes together. smile

mx-6

5,983 posts

213 months

Tuesday 4th April 2017
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sleepera6 said:
Oh dear, sobering reading that, I which I hadn't looked. Some rare and interesting retro classic motors in the bin there. frown