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Oct 29, 2013 20:38:50 GMT
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Last Edit: Jan 3, 2015 0:40:04 GMT by jondimond
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Oct 29, 2013 20:46:34 GMT
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Now I knew that there was a suspicious amount of underseal on it, so I knew some nasties were hiding under there. I wasn't expecting quite as much though. I really like this little truck, so I bit the bullet and decided that the only way to sort this out properly was to part the body from the chassis. So I started to strip as much of the body as I could easily do.    I've got all of the body mount bolts off. I'm hoping I can get the body off without having to pull the engine as it's more effort. So I've got to disconnect the brakes, wiring etc to the engine, steering, shifter mechs, clutch line etc. I'm going to make a big dolly for the body to sit on, so that I can wheel it around. I think I'll tackle the chassis first. The big metal gluing machine is going to be getting a workout! |
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Last Edit: Oct 29, 2013 21:07:01 GMT by jondimond
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Oct 29, 2013 20:49:33 GMT
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Good to see a mk1 shogun on here, looks like your going to be having some fun with the welder with this one, I will be watching your progress, more pictures please
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MK2 Cortina Estate
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Oct 29, 2013 21:04:30 GMT
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Good to see a mk1 shogun on here, looks like your going to be having some fun with the welder with this one, I will be watching your progress, more pictures please I'll try and post updates as soon as I get the work done. I really like the Mk1 shogun, especially the little SWB one. It's probably not the most capable off roader, but I don't really care. To me it's a much cheaper option than the G wagon I really want and can't afford. |
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recarouk
Yorkshire and The Humber
Posts: 435 
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Oct 30, 2013 20:01:57 GMT
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oooo love this, that garage is awesome too  |
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Oct 30, 2013 20:02:11 GMT
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Jeez, i thought old Disco's could rot, still probably not bad for a 23 year old 4x4.
Fair play taking the body off, only way to do it properly.
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72 Pontiac Firebird Formula 400. 95 BMW E34 525i Manual. 80 Lotus Elite, sold  86 Mk4 Escort RWD V8, sold |
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Oct 30, 2013 20:16:21 GMT
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Thats unbelievable!! ours is an 86 lwb 7 seater in daily use,and hasnt any rust worth bothering with on it!!downside no intercooler upside the pump and the turbo I have "tweaked" and it produces a little more than the original 78 horsepower lol
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Oct 30, 2013 21:01:47 GMT
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I was a bit surprised at the amount of rot too to be honest. I must admit that I didn't check too thoroughly when I bought it as I knew I could fix it and it had a 12 month ticket. This one is a 2.6 four pot petrol. I was after a diesel really, but this one came up and I really liked it and the MPG figures aren't that different. The only real advantage of the diesel is running it in deep water. I spent today knocking up my dolly. The base is a window frame that never got fitted (I think it was mismeasured). It makes a perfect dolly though. I attached 4 machine mart castors. I think these ones are rated at 100kg or 125kg each. The rest of it is made out of some old joists that came out of a barn conversion we did a couple of years ago. It's only mocked up for now, but tomorrow I'll screw and glue it properly. It seems 'reet sturdy so far, but as I've got to be underneath the body, I'd rather it was really strong. It sits under the centre 4 body mounts, pretty much at both ends of each sill. I'm hoping this is a pretty good balance point.   |
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Last Edit: Oct 30, 2013 21:02:15 GMT by jondimond
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We started at about 1 today, with all of the wiring, cabling, linkages etc to remove. By about 4 we were ready to start lifting. I'd like to say it all went swimmingly, but it was an  ! We missed a couple of things, a few brake lines needed cutting after the unions rounded off etc. My dolly was the wrong size, so it needed some modification. I should measure more accurately in future. However, it's off!! My garage looks like a bomb hit it. We were knackered when it was finally separated and on the dolly at 8:30. So tidying up will have to wait for tomorrow. In the mean time, here's a couple of pictures.    |
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This one is a 2.6 four pot petrol. I was after a diesel really, but this one came up and I really liked it and the MPG figures aren't that different. The only real advantage of the diesel is running it in deep water. bit like land rovers of the same era then, diesel version lets you have slightly less terrible fuel consumption  really interesting thread actually, its sort of a monocoque shell ontop of ladder chassis, rather than the sort of modular bolt on land rover style. must make for pretty sturdy vehicle. keep up the good work (and photos ! ) |
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This one is a 2.6 four pot petrol. I was after a diesel really, but this one came up and I really liked it and the MPG figures aren't that different. The only real advantage of the diesel is running it in deep water. bit like land rovers of the same era then, diesel version lets you have slightly less terrible fuel consumption really interesting thread actually, its sort of a monocoque shell ontop of ladder chassis, rather than the sort of modular bolt on land rover style. must make for pretty sturdy vehicle. keep up the good work (and photos ! ) :lol: at 'slightly less terrible'. I think mid 20's are the absolute best you can hope for with these things. I don't go that far in it though, so economy isn't a massive concern. It's mainly just a toy Being able to lift the shell as one unit is really handy. It's tricky with the engine still in as you have to lift it pretty high, but it's all doable. I had a bit of a pick around the chassis today, took a ropey looking patch off and well, I'll let the pictures do the talking....     |
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yowser, but kudos for getting stuck in there ! repaired similar area on my swb (i.e. in the splash zone off the rear wheel)
can you get repair sections (outriggers and cross members and such) or is it all gonna be hand bent 2mm ?
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I used to work on these when they were new, and did a couple of chassis swaps on em due to incorrect towing knackering the rear crossmember. Hindsight says I should have stashed those old chassis and not weighed them in !! We had advantage of a 2 post lift to do em so credit for you doing it garage. Seeing the rot on this means I really need to blather my Mitsubishi L300 with waxoyl.
Good luck with the rebuild and look forward to seeing how you progress.
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yowser, but kudos for getting stuck in there ! repaired similar area on my swb (i.e. in the splash zone off the rear wheel) can you get repair sections (outriggers and cross members and such) or is it all gonna be hand bent 2mm ? I must say it's a lot worse than I anticipated, but it's scrap it or fix it, so I'll have to fix it. The only panels I can find for these things are the rear quarters on the body. The chassis is 3mm steel I think, (well that's what I've bought). I made that little press bender to do most of it, but the outriggers etc will have to be salvaged as well as possible or remade as well as possible. I can't imagine that thicker steel will do any harm, it's not as if they've thought about crumple zones! |
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I used to work on these when they were new, and did a couple of chassis swaps on em due to incorrect towing knackering the rear crossmember. Hindsight says I should have stashed those old chassis and not weighed them in !! We had advantage of a 2 post lift to do em so credit for you doing it garage. Seeing the rot on this means I really need to blather my Mitsubishi L300 with waxoyl. Good luck with the rebuild and look forward to seeing how you progress. I really wish I still had access to a 2 post. It would have made the body lift so much easier. It's done now though . Thanks for the luck, I might well need it. Will update later this evening if I can escape to the garage for the afternoon. |
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MK2VR6
Posted a lot
Mk2 Golf GTi 90 Spec
Posts: 3,328
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Intriguing thread. Hats off to you for going for it! Mk1's seem really thin on the ground now, so if you have the skills (which you clearly have), it's nice to know another is being saved. I helped pull the engine from a tidy old mk1 a couple of years back, to go into a mk2. My brother was behind the idea, and his weekend toy at the time was a J Top mk2 - also stupidly rare. Unfortunately no longer with us.
Anyway, bookmarked; keep us updated!
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Intriguing thread. Hats off to you for going for it! Mk1's seem really thin on the ground now, so if you have the skills (which you clearly have), it's nice to know another is being saved. I helped pull the engine from a tidy old mk1 a couple of years back, to go into a mk2. My brother was behind the idea, and his weekend toy at the time was a J Top mk2 - also stupidly rare. Unfortunately no longer with us. Anyway, bookmarked; keep us updated! I'm not surprised that there are few left if they rust like this one. I guess the rust protection from the factory wasn't great, certainly on the chassis. There's some fairly ropey looking factory welds on there too, full of porosity as if they were done without shielding gas. I looked at a few Mk2's as I quite like them too, but the full retro styling of the Mk1 had to win the day I had an hour or two in the garage this afternoon. I must admit that my enthusiasm wasn't top notch today, so I only got a bit done. I cut the rest of the chassis leg of the rear cross member, which as you can see is also knackered. I also tweaked my little press bender to get the right sort of radius for the repair sections. Hopefully I'll have a bit more drive tomorrow and make some real progress, but for now here's today's pics.   This is the rear spring hanger  |
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Nov 10, 2013 20:13:14 GMT
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I made a start on the repair sections today. A bit of slow progress as there was a bit of trial and error getting the profile right. I'm having a bit of trouble getting the bends to go to 90 degrees, but I've got an idea to try out tomorrow. One thing I discovered though, a 57mm holesaw will drill a 58mm hole, not the 60mm hole I'd hoped it would. I'll have to dremel these ones and await a 60mm one from ebay. Anyway, Today's photos.  I've still got to weld the captive nuts in  |
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actionslaxx
Part of things
a message to you rudy
Posts: 74
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Nov 11, 2013 18:00:38 GMT
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depressing and fantastic at the same time, top work.
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