Alex's Garage: Project Blackbird

[Alex_FC]

Hi,

I have been working on my Black GSI (aka the SKIP, see number plate) for a few weeks and thought I would post my progress, mainly because any good ideas offered by other members is always a bonus.

I bought the car a around 18 months ago, and it wasn't the best purchase I ever made. It has been pretty much sat on my drive doing nothing and I had been scavenging bits off it (like the axle) to keep my Diplomat going.

The plan is to get it drivable again by the year end, then MOT'ed after winter.

The main problem was Rust/Rot, and trust me when I say I have been temped to just put it on the scales.

[Murph]

We'll need a shed load of pics Alex!

[Alex_FC]

<a href="http://s572.photobucket.com/albums/ss164/tomoaac/?action=view&amp;current=IMG_0724.jpg" target="_blank"><img src="http://i572.photobucket.com/albums/ss164/tomoaac/IMG_0724.jpg" border="0" alt="Photobucket">[/url]

[Murph]

Link fixed:
Clicky

[Alex_FC]

Might not look like much, but the Rot came from the inside of the wheel arch, and I had to make a big hole to get back to metal. Other side had the same issue.




can you see the massive hole? it had been plated on both side in the same location and just Rotten through again, I bought the car with 1 years MOT, got know how it passed.

[Alex_FC]

This is my first fix, I used 3mm thick Mild steel Sheet (My first time working on a car body, soon realised I was using ship building techniques that were not appropriate.


lesson learned and bought some 1.5mm sheet, this was much easier to bash into shape, and a bit of body filler an who would know.




Under-side: filled in holes with 3mm, and wire bushed the lot, followed by white spirit clean, then primer and finished in Matt Black. I still need to used under body sealer on the high impact areas.



Part of the rear panel needed cutting out and I used 1.5mm sheet again and made the seam for the rubber seal to locate onto.

[Alex_FC]

This is some structure I put into the spare wheel well, The purpose is for a battery box I have made to locate the battery in the boot. Seems logical to me.



The boot I have taken up that rubber sealant stuff (horrible job), wire brushed, cleaned, primed and finished in Matt Black, you may notice the strengthening bar this was just a bit of fun.

[Pedro]

Good work, fella!
 

[Catho]

Hi Alex, this is spooky....

I work in Castle Donington, a guy I work with has been telling me of a Black GSi around the corner from where he lives in Long Eaton...............is this you???

He tells me there is/was a purple Jag on the drive, and now there is another Carlton on show (Silver?).

I said I'll have to pop round and knock on the door for a chat about said cars. I was going to pop a post on here (a long shot, I know) asking if anyone in Long Eaton with a Black Gsi on the drive was on this forum....low and behold I may have found them (if this is you).

Incidentally, your car is in the exact same condition mine was in when I bought it (almost identical in the amount of rust and in the same places....80's/90's Vauxhalls, don't you just love 'em)

Did the same as you in the boot (after I'd welded both inner quarter panels/boot floor, brush sealed the seams etc...).

Link to my 'work in progress' thread:
http://totalcarlton.com/forums/index.php/topic,12187.0.html

[Alex_FC]

Yes it is me!!

I have just had a look at your car, wow amazing stunning.

I now feel ashamed of my car and work, in comparison.

The truth is I have hated the ownership of the Carlton, but at the same time it just looks amazing and some how compliments me.  I feel its the sort of car I should drive.

The silver Diplomat I bought because its so-solid and I had the parts car (GSI), it cost less than £300 and had 10 months MOT, I drove it like a hire-car until the MOT ran out, almost problem free apart from the rear axle. I plan on keeping the shell for the future.

The pimp Purple Jag I smoked around in that for a few months, and by smoked I means loads of happy burn-outs. £600 for a 4.0 supercharged jag and it had a full year MOT (You can see in one of the rusty pictures).  Doubled my money breaking it up and still have the engine, gearbox, supercharger. The interior made nice lounge furniture.

Hi Alex, this is spooky....

I work in Castle Donington, a guy I work with has been telling me of a Black GSi around the corner from where he lives in Long Eaton...............is this you???

He tells me there is/was a purple Jag on the drive, and now there is another Carlton on show (Silver?).

I said I'll have to pop round and knock on the door for a chat about said cars. I was going to pop a post on here (a long shot, I know) asking if anyone in Long Eaton with a Black Gsi on the drive was on this forum....low and behold I may have found them (if this is you).

Incidentally, your car is in the exact same condition mine was in when I bought it (almost identical in the amount of rust and in the same places....80's/90's Vauxhalls, don't you just love 'em)

Did the same as you in the boot (after I'd welded both inner quarter panels/boot floor, brush sealed the seams etc...).

Link to my 'work in progress' thread:
http://totalcarlton.com/forums/index.php/topic,12187.0.html

[Sleepyboy]

I work in Castle Donington,

Who for?

I am now working in Castle Donington for the next couple of years, might bring the CDX to work one day!

 

[Catho]

Yes it is me!!

I was discussing it at work today with my mate from LE, said it was too much of a coincidence not to be you (him telling me about this black GSi he's seen, and me seeing this thread), finally I put two and two together.

There seems to be a good number of us in the (East) Midlands with Carltons (400-Ascona has a 24v and a Lotus, myself, you, Dave the Builder's in Swad. and a good few more no doubt.....common as muck aren't we!!)

I now feel ashamed of my car and work, in comparison.

Don't be. It's taken me years (and a fortune) to get it to this stage....and it's STILL not on the road. I've gone way over the top with this 'project'. It won't be until next year now that I get it back on the road. 

Who for?

I am now working in Castle Donington for the next couple of years, might bring the CDX to work one day!

I work for a company called Brownett Ltd (Reprographics, design & print) on Trent Lane.

Where are you working? Definitely rock up in the CDX, I'll pop across for a chat 

[Pedro]

Can you all feel the TC lurve going round Castle Donington?

Don't get too close, it's catching..............

[Alex_FC]

Bought Some HEL Brake lines, decided to go with these because they have Stainless Steel fittings, unlike the Zinc plated ones usually found on Goodridge lines. They also have a plastic sheath that protects the braided hose, I am impressed by them.

I will be making up some brake pipes as well, for me Cupra-Nickel is the only option.

[Alex_FC]

The old Rear brake Calipers, previous owner though Red would be a nice colour




Stripped and castings are ready for Acid dipping,  I have the rebuild kit for them already.
2 of the 4 pistons have pretty bad score-marks on them, not happy about that, I wouldn't know where to get new ones from. Any ideas?

[biffbangpow]

good work mate !
we all know a good welder or 3 <lol

BLACK IS THE COLOUR !!!

[carlton_mad]

i may have a pair of good used calipers here if that is of any interest??

[Alex_FC]

38mm pistons?

If so yes, how much do you want for then with postage?

Regards

[carlton_mad]

i will look tomorrow and if i have them ill let you know!!

[Alex_FC]

So yesterday I contacted Bigg Red (The caliper re-manufacture company) to ask if they have any 38mm pistons available.  The answer was yes and stated around £19, I though perfect I can cope with that, until the guy said £19 per piston, plus a £15 postage charge because they were located in Germany.   I obviously said forget it, £53 for one caliper in pistons alone. The idea of rebuilding them myself was to save money.

Forgetting the pistons,  rebuilding one piston myself will cost,  £14 for the rubber seals, £10 for the acid dip and £8 for the very-high-temp enamel paint.  Hence, £32, plus the knowledge they have been done right and will look good (Hopefully).

[carlton_mad]

found them dude are you still interested?? £40 posted??

[Alex_FC]

found them dude are you still interested?? £40 posted??

I have got to try and keep spending down,  The approach I am going to take is hand dress the 2 scorn pistons and fit them both into the same Caliper.  Then if I have trouble with it, I will get in touch regarding the calipers you have.

Hopefully they will be fine and its just me being over concerned.

Thanks Carlton_mad for having a look.

[Alex_FC]

One hand made battery tray.



One battery tray fitted.



Now with the battery in,  next job is to run the positive to the front.

[DevonGSi]

Why move the battery to the boot?

[Alex_FC]

Why move the battery to the boot?

Well it takes up room in the engine bay, room I will need next year.

Plus nothing spoils an engine bay more than clutter,