1988 Mk2 Cavalier 1.8GLi

[sleag40]

Still very short on time for this at present, but the demands on my free time should be dropping in the next week or so.

Track adjusters were cleaned up and wound back in.



Cleaned up some more pieces before a painting session was due.



Painting session yielded some fresh looking parts for reassembly.



Steering rack put back together ready for refitting at a later date.



Stub axles, hubs and drums separated, bearings removed then cleaned up.



My rear beam should be powder coated in the next week or so - once its been put back together, there's just the drive shafts and brake servo to sort, and all the gubbins are done. (deep joy of getting the bodywork ready for paint imminent!)

[sleag40]

Got a couple of bits painted this week. New bearings fitted before the rear hubs were done, and stub axles painted too.



Brake drums were cleaned up and painted.



Should get the rear end built back up when I get my rear beam back next week.

[teaboy]

You’re doing a very thorough job.

[sleag40]

Grabbed a bit of time for this earlier. Master cylinder and servo as removed.



Master cylinder and reservoir bottle were dismantled and cleaned up.



Made a start on getting the servo unit ready to paint.



Hopefully get these bits prettied up and reunited over a couple if evenings this week.

[johnthesparky]

It’s lovely to see your work

[redexstyle]

Strong work.

Can't wait to have my Cav's bodywork sorted, albeit by someone else haha.

[sleag40]

Servo chamber hit with POR15.



It was then rubbed flat, and given a coat of etch primer, followed by two coats of satin black.



After hardening, it was put back together with the master cylinder.



Drive shafts were stripped, cleaned, re greased and some paint was splashed about.





Still waiting for the rear beam to be done.

[redexstyle]

Steve - have you a pic of your rear beam please?

I've just refurbed one for my other Cav, but it has different handbrake cable mountings. The old beam has the slider on it so trying to figure out if I can attach handbrake cables without the need for a slider?

If that makes sense lol?

[darrenh]

small details that will collectively set the car apart from many others

[sleag40]

Jun 29, 2020 7:33:11 GMT redexstyle said:

Steve - have you a pic of your rear beam please?

I've just refurbed one for my other Cav, but it has different handbrake cable mountings. The old beam has the slider on it so trying to figure out if I can attach handbrake cables without the need for a slider?

If that makes sense lol?

I'll get you a picture when it comes back from the powder coaters chief.

Not a lot to report this week - bit of brake line fettling.

Once all the proprietary black filth was removed from the rear beam brake lines, it revealed that they were in really good nick. There was just a couple of small areas where the protective green coating had been breached.



The green coating was removed with emery cloth, and the unions were de rusted with the help of Deox gel.



Eventually they were given two coats of POR15 gloss black, and are now ready to put back into service. (should be good for at least another 30 years).



Master cylinder to front brake lines are in process.



Rear beam still not done yet.

[sleag40]

Stuff has been happening - front brake lines were finished.



Rear brake stuff assembled ready for fitting.



Powder coating now back with me.

[sleag40]

Time was in short supply, but I got the brake gubbins fitted.



Brake lines and anti roll bar went on too.



Just need to fit the beam mounting bushes and it can go into storage until the time comes to fit it.

[redexstyle]

That looks really fresh Steve. Almost too good to use lol

I'm planning the same on my blue Cav but for the green one, I've just sanded down and used Hammerite.

Once I get that fuel rubber hose sorted and the filler neck, I can refit the rear beam.

[sleag40]

Rear beam bushes were pushed in with next doors" hydraulic press.



Mr Haynes suggested using threaded bar and "distance pieces". Definitely easier said than done.

Now all undercarriage gubbins is ready for action, attention can be turned towards getting the bodywork ready for paint. I need a new compressor before I can get some epoxy primer on there, so I aim to get that sorted before I bare metal all the areas requiring bodywork. "Just" a paint job away from reassembly now.

[darrenh]

theres no way on gods earth that hardware store M10 studding would pull those bushings in

[sleag40]

Time has been in short supply again, however, all the nice ready to fit stuff has been packed away to keep it all clean and dry until reassembly commences.

All the rubber bungs for the underside have been cleaned of all sealant and muck ready to go back in.



A couple of bungs were missing from the spare wheel well - if anyone has any spares, or knows of somewhere that sells them I'd be most grateful.

The gear selector gubbins had cleaned up pretty well a while back, but was now filthy again. A better job was done, then it was wrapped up and packed away.



Had a good look at all the work done on the under side, no rust has appeared, so I'll get stuck in to scotching it all in preparation for applying the stone chip coating.



Once my new compressor arrives, I can start making some decent progress on the body.

[VW]

Jul 23, 2020 18:37:18 GMT sleag40 said:

Had a good look at all the work done on the under side, no rust has appeared, so I'll get stuck in to scotching it all in preparation for applying the stone chip coating.



Once my new compressor arrives, I can start making some decent progress on the body.

Looks great under there!
Can't remember what this coating is, what's your process underneath, clean up metal, this coating, stone chip, then paint?

[sleag40]

Cheers! Process is bare metal, Hydrate80, epoxy mastic (3 coats) Gravitex stone chip, then a Liberal coat of Dynax UB to finish. Obviously I'll leave the wax application until all the paintwork is done.
Compressor has landed.



Need to rearrange a load of junk and mk2 bits to fit it in by a wall, then after a monster cleaning session (ridiculously dusty in the shed at present) I can finally get back to the bodywork.

[sleag40]

Didn't fancy a cleaning session with today's available time - thought that I'd tackle a job that I've never done before. That job was the removal of bonded glass.



I'm sure its a lot easier with the correct tools, but a Stanley knife, plastic card and a screwdriver, along with a bit of bloody minded perseverence, saw the job done without damaging the glass. The glass in the replacement tailgate is heavily scratched, so the glass from the original tailgate needs to be re used. I'll probably smash the damaged glass out of the replacement tailgate to save time.

[shielsy68]

Doing a fantastic job on that, youl put the mot out of a job