Another Chassis Refurb
Discussion
Well,
After months of deliberation, I've decided to get on with it! My 1998 4.2 is showing distinct signs of brown chassis fungus (outriggers through on top, upper members in the engine bay perforated, upper wishbones...) so I've taken the plunge. She's in a workshop that's a bit larger than my 9-foot (!) garage - should be enough room I hope.
The "scope" at the moment is:
- full body lift
- chassis shot blast, repair, hot zinc prime, powder coat (although I'm open to suggestions on priming and coating)
- diff refurb (pinhole leak)
- polybushes all round
- drop links
- possibly shocks (gaz golds on the rear only at the moment, original billys up front ...)
- engine bay heatshielding
- coolant hoses
- repaint, at least front end
Clearly, this list could grow as I drain the swamp...
Progress on the first evening: seats out, helmet holder out. Only had to grind one bolt!
After months of deliberation, I've decided to get on with it! My 1998 4.2 is showing distinct signs of brown chassis fungus (outriggers through on top, upper members in the engine bay perforated, upper wishbones...) so I've taken the plunge. She's in a workshop that's a bit larger than my 9-foot (!) garage - should be enough room I hope.
The "scope" at the moment is:
- full body lift
- chassis shot blast, repair, hot zinc prime, powder coat (although I'm open to suggestions on priming and coating)
- diff refurb (pinhole leak)
- polybushes all round
- drop links
- possibly shocks (gaz golds on the rear only at the moment, original billys up front ...)
- engine bay heatshielding
- coolant hoses
- repaint, at least front end
Clearly, this list could grow as I drain the swamp...
Progress on the first evening: seats out, helmet holder out. Only had to grind one bolt!
Smithies said:
Good luck to you. I'm undertaking the same project. The body was lifted off on Sunday and sitting in mrs s's space on the drive. All goes well should have the engine and gear box on the work bench this weekend(roll on)
Sounds like you're making good progress - I had read that it's difficult to get the body off with the engine in place - how did you find it?DAVEY DEE said:
And don't forget the idiots guide for me! 
I could test its value for idiots.
I'm referring to some superb idiots' guides already, this being one of them:I could test its value for idiots.
http://pistonheads.co.uk/gassing/topic.asp?h=0&...
I'll try and add to them where I discover new pitfalls...
Pictures soon.
Hawkeye1922 said:
I'm referring to some superb idiots' guides already, this being one of them:
http://pistonheads.co.uk/gassing/topic.asp?h=0&...
I'll try and add to them where I discover new pitfalls...
Pictures soon.
Good luck with it, will be worth it in the long run http://pistonheads.co.uk/gassing/topic.asp?h=0&...
I'll try and add to them where I discover new pitfalls...
Pictures soon.
some pictures as promised:
Engine mostly disconnected - to be on the safe side I'm taking off what I can before lifting, although I'm hoping to get away without taking the front crank pulley off. You can already see plenty of rust where the manifold runs close to the chassis.
Propshaft now off - that was quite easy - just four bolts in the holes visible. The diff has clearly been leaking - refurb time.
The gearbox, viewed from the rear, lowered slightly to expose the two bolts connecting the gear lever - you can see a socket on one of them. The gearbox support bracket is visible on the floor.
And the gearbox is out. I've managed to secure the loan of an engine crane - just need some straps, so that's the next thing on the shopping list. i also managed to get the bellhousing and starter motor off tonight, so should be ready to lift very soon...
Engine mostly disconnected - to be on the safe side I'm taking off what I can before lifting, although I'm hoping to get away without taking the front crank pulley off. You can already see plenty of rust where the manifold runs close to the chassis.
Propshaft now off - that was quite easy - just four bolts in the holes visible. The diff has clearly been leaking - refurb time.
The gearbox, viewed from the rear, lowered slightly to expose the two bolts connecting the gear lever - you can see a socket on one of them. The gearbox support bracket is visible on the floor.
And the gearbox is out. I've managed to secure the loan of an engine crane - just need some straps, so that's the next thing on the shopping list. i also managed to get the bellhousing and starter motor off tonight, so should be ready to lift very soon...
Rufus Roughcut said:
Also following this thread with interest, I'm sure my 98 isn't far off needing a body off.
Keep up the good work and loads of pics please
You would be suprised what lies under our nice shiney bodys,its nice to see the rust and shabby powder coat coming off;).we are planning to move next year and a double garage is a must have for me now,as soon as i have the room my body will be removed.Keep up the good work and loads of pics please
Thanks, all, for your kind words!
My next problem is lifting the engine - does anyone know the best lifting points for chain or straps? Is there a good bolt hole to put a lifting eye on? I think I've seen a thread where someone put a chain through the A/C compressor bracket - does this work? Having taken the bell-housing off and not the front pulley I wanted to try to lift fairly vertically...
My next problem is lifting the engine - does anyone know the best lifting points for chain or straps? Is there a good bolt hole to put a lifting eye on? I think I've seen a thread where someone put a chain through the A/C compressor bracket - does this work? Having taken the bell-housing off and not the front pulley I wanted to try to lift fairly vertically...
bikealarmblair said:
What colour are you coating/painting the chassis? I always think that white lets the cars down as it gets so dirty.
Good question. I suppose I've got to decide whether I want it to stand out or blend in. I was thinking battleship grey or black to prevent the outriggers being too visible from the side of the car. But having seen a few beautiful examples on here I might go for something brighter - can you get powdercoat in orange/purple flip?? 
Well, we got it out tonight! Massive thanks to my good mate Adrian for all his help so far.
The crane is just bearing the weight here while the front engine mount plates are removed. It's not that clear in the pic, but we didn't have to undo the steering linkage. Having removed the N/S exhaust manifold allowed us to move the engine over to give just enough clearance to tap and wiggle the O/S mounting plate out from under the linkage. JensenA, you were right about the general weight and manouverability.
Out it pops!
...where the engine used to be...
The chassis rust in the vicinity of the manifolds is quite shocking - I can't believe there's no heatshielding at all here. Definitely something to add in the rebuild.
The crane is just bearing the weight here while the front engine mount plates are removed. It's not that clear in the pic, but we didn't have to undo the steering linkage. Having removed the N/S exhaust manifold allowed us to move the engine over to give just enough clearance to tap and wiggle the O/S mounting plate out from under the linkage. JensenA, you were right about the general weight and manouverability.
Out it pops!
...where the engine used to be...
The chassis rust in the vicinity of the manifolds is quite shocking - I can't believe there's no heatshielding at all here. Definitely something to add in the rebuild.
Wait till you start grinding it'll scare you just how weak/rusty some of it is.....
Hawkeye1922 said:
Good question. I suppose I've got to decide whether I want it to stand out or blend in. I was thinking battleship grey or black to prevent the outriggers being too visible from the side of the car. But having seen a few beautiful examples on here I might go for something brighter - can you get powdercoat in orange/purple flip??
I'd go boring black I dont even want to look at my front end yet
My bum has had a few near misses on the back end bits so far,mine looked way way cleaner than this but it amazed me once i really got into it,Got to agree though there are definately some bits that are really not designed to last
.Hope all goes well sir think the route your taking is the right one cos its a pain trying it with the body in place
My bum has had a few near misses on the back end bits so far,mine looked way way cleaner than this but it amazed me once i really got into it,Got to agree though there are definately some bits that are really not designed to last.Hope all goes well sir think the route your taking is the right one cos its a pain trying it with the body in placeHaven't updated for a while - had an unbelievably busy December. The body was lifted late November:
Partly lifted and supported on fence posts, trestles and props!
The rolling chassis (got this far just before Christmas):
A candidate for the rustiest outrigger trophy?
Thursday last week we finally got the chassis completely stripped. All that remains now is to get the wishbones off the hub assemblies and it's then ready to go for repair.
Partly lifted and supported on fence posts, trestles and props!
The rolling chassis (got this far just before Christmas):
A candidate for the rustiest outrigger trophy?
Thursday last week we finally got the chassis completely stripped. All that remains now is to get the wishbones off the hub assemblies and it's then ready to go for repair.
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