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Catho
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« on: May 08, 2011, 05:04:37 PM » |
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Plans for the Gsi at the weekend include: * Finish prepping front bumper (wet/dry, scotch) ready for paint. (top of bumper will be re-textured) * Finish prepping front grille '' ''* Get Bump Strips re-textured and painted (black) * Get bonnet prepped and ready for paint.* Fit gas strut mounting plates (from Senator) to underside of bonnet.* Fit windscreen to car. (and wiper arms/blades)* Get Flywheel back on Engine (provided my trip to the bolt supplier is successful!!)* Treat myself to a beer after a day of Carlton tinkering.Bumper in primer, flatted down with 800, then 1000 grit Wet & Dry.   Front grille flatted with 1000 grit.  Slight crack in corner fixed, filled and flatted.  Gas strut plate (from senator) in position ready for being marked.   This area has to be stripped to bare metal for the glue to work...   Back of plate stripped back to bare metal too.  Glue applied to back of plate...  Clamped into position and sealed...  Side of plate riveted to edge of bonnet with steel blind rivets for extra strength...   Plates fixed and ready for paint. (look a bit untidy at the moment, but once painted they should look like part of the bonnet)...  My new bolts being cut down on lathe...   And the head reduced to match originals...   Flywheel ready to be mounted back on engine...  Homemade locking tool at work...  Torquing up bolts...  Rest of work to be done next weekend...hopefully  |
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« Last Edit: June 22, 2011, 09:00:14 PM by Catho »
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After 10 years........she's back on the road!!!
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doz
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« Reply #1 on: May 08, 2011, 05:18:49 PM » |
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Just a quickie question. The rear main seal. Did you slap some grease round the lip when you fitted it or did you leave it dry?
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Wafting air biscuits up the noses of the bureaucrats since 1970
92 GSI 24v manual
92 LC
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Catho
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« Reply #2 on: May 08, 2011, 05:30:06 PM » |
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Good question, I couldn't find anything in the manual telling you to grease it, so I ran some clean oil around it and inside the drive where the gearbox shaft spline sits, so it's not dry.
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After 10 years........she's back on the road!!!
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chrismec
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« Reply #3 on: May 08, 2011, 06:01:26 PM » |
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Good work done there matey  Going to fit struts to my bonnet but was going to weld them as I've got to paint car anyway but didn't think of glueing them  what did you use? |
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Catho
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« Reply #4 on: May 08, 2011, 06:27:27 PM » |
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It's a trade glue/bond called 'metal to metal' once it sets it's as good as a weld (I believe It's used on Peugeots when fitting some of their panels). No need to worry about damaging paintwork on the surface of the bonnet either. I riveted the sides as a double measure too. |
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After 10 years........she's back on the road!!!
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Land-Barge
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« Reply #5 on: May 08, 2011, 06:34:03 PM » |
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Nice work with the bonnet struts  |
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melinx
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« Reply #6 on: May 08, 2011, 09:48:29 PM » |
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Superb work Mark and very informative photographs: A good tip about the glue, I must remember the name of that one !
A minor point that I forgot to mention in our chatting; I don't think it's at all important for the work you've done but it's worth keeping in mind in future for anything load bearing.
I'm not sure what you mean by blind rivets ? but open rivets will pull metal together with much greater force than sealed rivets (it's called the clench)
A bit of knowledge and personal experience since I ran the electronics lab at Tucker Fasteners R&D dept. for 10 years.
Keep at it !! I'm busting to see that work of art up and running
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« Last Edit: May 08, 2011, 10:13:52 PM by melinx »
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Catho
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« Reply #7 on: May 08, 2011, 11:23:54 PM » |
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Nice work with the bonnet struts Thanks LB. Thanks Mel. I believe a blind rivet is used when you can't see or get behind the thing you're riveting, I have a box of them as they're what I'm using to rivet the window mechanism back in the door. I'm only really using them as a 'belt & braces' precaution, this bond is good, but the bonnet is a fair weight to be lifted I thought I'd err on the safe side |
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After 10 years........she's back on the road!!!
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melinx
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« Reply #8 on: May 09, 2011, 07:12:58 AM » |
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The visible difference between open and sealed rivets is that you can pull out the mandrel of an open rivet, but with a sealed rivet, the only way to get the mandrel out is to set it because the rivet is formed around the mandrel.
The use of the rivet is an excellent idea because bonded joints are VERY strong in tension and shear; the enemy of a bonded joint is peel stresses which make them far more likely to fail eventually.
Riveting around the edges of a bonded joint stops any peel stresses being applied to the bond
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Catho
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« Reply #9 on: May 09, 2011, 07:40:33 PM » |
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Checked the bonded plates tonight (takes 24hrs for it to completely cure) and they're going nowhere!!! Like a limpet on a rock ....besides, I don't plan on being under the bonnet much anyway....  |
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After 10 years........she's back on the road!!!
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melinx
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« Reply #10 on: May 09, 2011, 08:40:49 PM » |
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....besides, I don't plan on being under the bonnet much anyway.... Maybe not, but I'll bet that the bonnet will be up with you sitting in a high chair admiring what's inside (just like I would) |
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Catho
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« Reply #11 on: May 09, 2011, 09:43:45 PM » |
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Okay, I might have a sneaky peek now and again |
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After 10 years........she's back on the road!!!
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g4rth
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« Reply #12 on: May 25, 2011, 08:40:49 PM » |
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great work mate..and a good write up, nice reading |
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Catho
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« Reply #13 on: May 25, 2011, 08:59:14 PM » |
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Cheers pal. Hoping to get a bit more done this (long) weekend!
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After 10 years........she's back on the road!!!
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Catho
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« Reply #14 on: June 05, 2011, 08:02:16 PM » |
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Bonnet wet/dry flatted and ready to be taken to paint shop for another coat of hi-build primer and block flatted again, with bumper and grille.   Got some vinyl covers made up to put on the end of the sill covers/bumpers/front wing arch cover to help protect the paint against stone chips...    Wasn't too keen on having the 'cubby' left open as I know it'll be used to keep junk in and start to look untidy, so made up a blanking plate to hide the loose change and receipts behind... A trip to B&Q for the cabinet magnets and chrome handle...  Back of cover...   Chrome cover plate and flat black vinyl with reversed out logo/text...  In situ....  Perfect fit...  |
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After 10 years........she's back on the road!!!
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Murph
Administrator
Wanted: Life
Posts: 6301
Location: Dartford (Kent)
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« Reply #15 on: June 05, 2011, 09:16:40 PM » |
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That looks fan-bloody-tastic!
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melinx
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« Reply #16 on: June 05, 2011, 09:39:00 PM » |
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The work is to your normal standard Mark I think I see a problem though --- Those vinyl covers at the end of the sills are so good that they need something to protect them from stone chips |
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kevinfourlegs
The only TC member with four legs
Wanted: Life
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Am I the only TC member in south Wales?
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« Reply #17 on: June 07, 2011, 11:49:06 AM » |
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Top quality stuff. You could be on to something with that mod.
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RWD, as it was, as it is, as it should be for real men.
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Catho
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« Reply #19 on: June 22, 2011, 09:07:50 PM » |
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New windscreen and Bonnet fitted last night... Windscreen-less...  Windscreen fitted...  ...and polished.  Bonnet fitted...  Great finish (ignore the dust!!)  |
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After 10 years........she's back on the road!!!
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g4rth
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« Reply #20 on: June 29, 2011, 05:15:24 AM » |
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love those lifters... |
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stemo
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« Reply #21 on: June 29, 2011, 09:15:35 PM » |
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Bloody hell this is moving on quickly now...I bet it's really hard to keep the smile off of your face!  |
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Catho
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« Reply #22 on: June 29, 2011, 10:23:29 PM » |
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Not quick enough for me matey. Wanted her ready for billing, but sourcing the remaining parts and time (or lack of it) has hindered me slightly. Should be done for next years' Billing though..... Any smile on my face was swiftly wiped off it when I came to fit the Propshaft....what a nightmare!!!! Done it now, but working upside-down on your back underneath a 2 Ton barge with no room to swing a spanner, getting covered in underseal, cuts, bruises, sweat is no fun!!....ahh, the joys of restoration  |
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After 10 years........she's back on the road!!!
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nightmare
Sr. Member
Posts: 307
Location: Argyll Scotland
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« Reply #23 on: July 02, 2011, 12:50:34 PM » |
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Catho... I wish I had a workshop like yours Big clean tidy DRY lit Probably heated as well + understanding SWMBO Lucky man. ...All I've got is a yardmaster metal garage  . Not enough room to swing a rat! No room for cats Keep up the good work and enjoy it while it lasts because...... ...one day it will be finnished |
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Easy going untill PUSHED!!!!
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Street Sleeper
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« Reply #24 on: July 03, 2011, 12:20:48 PM » |
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Where'd you get the screen? How much did it set you back? Will need one for project tube eventually.....
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89 Project tube GSI 5800 16V!
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