Much school work and a little car work

So first some pictures of things that we finished last week but i forgot to take a picture of.

Good as new

Left door after its makeover

I had started to renovate the gear rod and now it is fixed.

Old vs new

I also took out the transmission so that we could get more room when working on the adapter plate.

I think it likes to be tied down.

Simon got out the brake pistons from one of the calipers. But on the other one the piston broke and we started to look after new ones. Alternative we buy a new caliper.

Left front brake is done. Now i just need to fix the brake pipe system.

Simon started to work on the right side door. Not as much damage as the left side so it soon was in working condition.
Then he moved along the right side and fixed various rust damages and old repairs.

Next week we have more time for the car and we hope we will get much progress done.

/Oskar

Santa is early this year

First thing first. This is how the engine room looked after Simon´s hard work and some paint.

We are going to do the final paint after the motor holder is in place.

Okay so we had already got the motor and controller but they forgot to send us the switches and control cables, and we have been waiting forever for them to send the rest of the parts.
When finally we got it, guess what, they still messed up and did not send all the parts we ordered.

The cooling pump, 3 switches and a battery gauge.

Cable that goes from the controller to all the switches. 

The motor that got delivered 3 months ago.

The controller that we got at the same time as the motor.

We also got a crazy big vacuum pump because PAF wanted to pay a little more when it comes to the brake system. 

The vacuum pump that also got delivered with the motor and controller.

 We also got our repair parts for the car.

Big package for big boys.

One of the many boxes we got.

Started to check if everything got delivered.

Simon started with switching out metal panels.

This is such a simple metal panel that we could have made it ourself but it did not cost much so what the hell.

Just doing some measurements.

Now Simon had taken away all the rusted metal and painted the inside.

I started to check on the breaking system and decided to start on the left front disc brake.
We had decided to keep the caliper and switch out almost everything else.

Let the transformation begin.

I did not get long in the process before i got a problem. The brake pistons were crazy stuck and we did not have the proper tools for taking it apart. So i have to go and borrow the right tools next week.

While i was at the brake i changed the shock absorber and painted the brake plate.

While i waited to fix the front brakes I started on the rear brakes.
And once more i got stopped in my tracks, we had forgot to order the brakeshoe self adjusting screws for the brakes.
So i started to work on the gear shift/transmission but i have no pictures of that yet.

Old to the left and new to the right.

At this point Simon was done with the panel at the back and had moved to the driver side floor step. 

I forgot to take a picture of how it looked before he started. But if i say RUST you maybe get the picture.

After a lot of measuring, 3 metal plates a fair amount of welding and a little paint this is how nice it got.

Simon got a whole 10 minutes of rest before he started with the next thing.

Next up was the door. It had much rust along the bottom side and it was basically the paint that hold it together.

A quick check if it was the right door we ordered.

All the rust have been cut away and we can see the entrails of the door. 

Only a little welding left and it can be mounted back on the car.

So this week we got much work on the car because we were free from school and we got most of our stuff.

/Oskar

More Bodywork

So this week Simon fixed the back hatch. 

First a little cutting

And after a little welding and some zinc paint it looks like this.

 After a week of cutting and welding your gloves might look like this.

Simon's hand reaching for help

 When we were looking under the car for damage we found a small rust area at the bottom side, and when Simon had ground away the paint we noticed that the area was much bigger then we thought. The paint and plaster was the only thing that hold the thing together. You can buy a replacement metal plate but it was so simple design that we had the neighbor metal workshop cut out and bend a metal plate for us.

The metal plate being held on place

So when Simon was about to weld it on place he noticed a weird thing. The metal in the non rusted area just melted like tin.

This is what fell of from the non rusted area.

So we started to take away more paint and we found a old repair. It had been point welded and then it had a tin like metal as a plaster.

The old repair we found

So we decided to wait a little and discuss how to best solve the problem.
In the mean time we started to fix small holes inside of the body.

Simon grinding off metal after welding shut some holes

 It was a crazy amount of holes.

Smooth like a baby's ass

Next thing was fixing the engine compartment. It had a little rust and we cut away a little metal that was used to the original motor setup.

Simon cutting away the holder for the old airfilter.

The evil rust is gone and new metal is here to save the day

Simon showing the metal who is the boss in this workshop

Welding it like a boss

We are still waiting on our parts and as soon we get them we are going to have a party.
I will update once every week of the work we do on the car.

/Oskar

Making one hatch from two

Today we worked on the back hatch and preparing for the blasting.
The back hatch on our car had a lot of rust on the bottom half and the lock was broken.

When we bought the car we got a extra back hatch and it looked all good except for a dent in the middle of it. But when I removed the window from it we saw that it had a lot of rust at the bottom of the window.

Here you can see the two hatches next to each other. The blue is the new one and the yellow is the one that had been on the car.
So Simon decided that he was going to cut out the good part from the yellow hatch and weld it on to the blue hatch.

Here we see the yellow part on top of the blue hatch. But the clock was running late and we decided that we were going to weld it together the next day.

Before we quit for the day i moved the motor in position for making some measurements for the connecting plate that is going between the gearbox and the motor.

The flying spaghetti monster gave the project its blessing.