Manky Monkey Motors

Well, here we are on the verge of another project. This belongs to Sue, my partner, who some of you know. She's aways wanted one and the chance came about a month ago when I found this one being advertised on the RodsnSods website. It was actually being sold for a friend by the guy who did the pinstriping on the portafold. Anyway, we left Surrey at 6 this morning and wound our way down to St Austell in Cornwall to collect it.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture070_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture072_640_x_480.jpg)

And now safely back at the shop in Hook.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture074_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture076_640_x_480.jpg)

I'm not starting this project right away, I need to finish the "hot rod" speed boat that's in the works, first. I'll start a thread on that soon.
Mean while we can be collecting bits for the Met, so we're ready to start when the time comes.

So, for ignoramuses like me - what is it exactly?

on one side it's got two wheels ontother its got three
both sides seem to have  wheels missing
it's no a unicycle (too many wheels)
it' not a motorcycle (too many wheels)
it's not a trike (too many wheels)
it's not a car (too many wheels)
it's not a bus / truck /artic etc (not enough wheels)
I give in

its a Nash Metroplitan (The same as Andy took photos of the other week in brock's shed)

http://en.wikipedia.org/wiki/Nash_Metropolitan


the other thing is called "A trailer"  ::)

As I wrote in the Wheels Day show thread back in the Spring:

A Nash Metropolitan. Very funky little cars. The doors are interchangeable & they were originally designed so that the front left wing could be swapped with the rear right one & vice versa, to cut down on factory pressings. My brother Brock & Scottie the hotrod haulier own one between them.

Here's 2 from that show.

.

And Scottie & Steve's.

Like road going bumper cars  :)
Looking forward to following the progress on this one Chris. Bet Sue's chuffed to bits with it!

liking that a lot.
talking about road going bumper cars, at the nats one of the bumper car escaped into the car park below the ride, no one was hurt though!!!! sorry off topic.

OK, so I thought I’d do a bit of an update on this project. The boat’s been put on the back burner for the moment.
Since Sue got the car in September, we’ve been buying parts that we know will be needed later on. Most of them have been sourced from The States, which we have sent to R&R in New Jersey, then shipped to the UK.
We have had a bit of a change of direction with the top end of the engine. Originally I was planned to use a big valve cylinder head and a pair of new Stromberg 97s, but whilst buying some other stuff, in his country, I got offered a Derrington/HRG cylinder head. This is a seven port, aluminium, cross flow head for BMC “B” series engines. There were approx 1000 of these heads made between 1958 and 1974, so reasonably rare. This one is number 78, made in July 1958, so right in the period for this car.
So in Oct/Nov I gave myself up and bought it (quite a few beer tokens). I did come with an inlet manifold though.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture103_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture095_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture097_640_x_480.jpg)

Once I’d got it home, I discovered what I though to be a crack in the top. If it was, I was in the s***. It was bought as seen, and I couldn’t afford for it to be a very expensive door stop!!
I had it pressure tested, and sure enough it was cracked (frost damaged probably). Now this head had been through the works about 7 years ago, new valves, valve guide, leaded valve seats, springs and fixing studs. I had never been bolted to a car since. So what to do?
Here’s the crack ……………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture101_1024_x_768.jpg)

This crack needed to be ground out for welding …….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture128_640_x_480.jpg)

Then took it to a buddy of mine to be TIG welded up ……….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture143_640_x_480.jpg)

It now required machining across the rocker post mounting platforms ……….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture148_640_x_480.jpg)

Now to make sure it wasn’t going to leak, I took it to a company in Slough (they specialise in impregnation sealing castings) … http://www.ultraseal-slough.co.uk/

So we now have a very expensive, but serviceable cylinder head rather than an expensive door stop.
I have also managed to purchase, off eBay, a pair of right in the period SU carbs to fit. Once I’ve cleaned an rebuilt these (I have the kits already) I’ll put some pictures up.

what head gasket do,es it use or what are you goung to use ,,only up at ,,wonderland,, ther,s a workshop pack,(i think  6 or 8 in it) of bmc head gaskets, bought for something special by my late father ,, if you give me some idea what the part number should be i,ll see if they are anything like next time i go up there ,,

I'll see what I can find re part numbers, but if the ones you have begin with the letter "C"  as in C-AEH 768 it's a good sign. If you could let me have the part numbers you have, to cross reference, it'd be cool. Thanks.

What does impregnation sealing involve Chris? -for the benefit of those of us that've never heard of it.

Non ferrrous castings (alli, magnesium, ec.) are very often porous. Ultraseal deal with all sorts of old things like classic and vintage heads and blocks, and also with brand new things like formula 1 gearbox casings etc.
So the item to be sealed has to be bare, as example this cyl head, no valves, studs, sender units, etc. If These items are left in the sealing medium acts like a superior version of loctite. All I left in were the brand new valve guides, if they ever need doing again whilst we have the car, we'll have them machined out or thin brass sleeves added.
So bare head, it gets put in a "vat", lid closed and vacuumed down. Once left for a while, an epoxy sealer is introduced and the vacuum colapsed. The last places that "hold onto" the vacuum are normally the porous parts and his helps pull the sealer into the porous parts. Quite simple really and not too bad a cost ( £85 to seal and thats twice and £25 to pressure test afterwards)
Ultraseals machines were installed in the land rover factory to seal the 3.9 blocks, some of which were porous. Think they were in other manufacurers factories as well.
Good company to know, been using them for years.

Never heard of that. Interesting.

Very interesting.

That was my job for umpteen years ; pressure testing all types of control ball/butterfly etc valves with various gases / fluids including full immersions .
Used clean rooms and worked with vacuum settings and pressures up to 20,000 psi on relief valves .
I worked with all the major gas/oil companies inspectors througout the world including the Russians in the 1970,s .
Used to use mercury manometers and got showered with mercury regularly every week in the late 1960,s and throughout the 1970,s .
Health and safety , my Ar*e .
.
I have bookmarked that company  :)
.
.

Just put a link in the commercial services threads   :)

Well, Santa visited Sue yesterday and left her 5 of these!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture163_640_x_480.jpg)

By golly she must have been good for years!

pretty very pretty

Well, I’ve got a bit of time between Christmas and New Year, so I’ve managed to get a bit done today.
First the crank was assembled into the block, back plate fitted and flex plate. Then the new small hitork starter, Checked out to make sure the starter engaged correctly and finally making sure I engaged and turned the crank over. All good there, so dismantled again ready to take block and crank for rebore, crank grind and full balance.
I pulled the old engine a while ago now, and the swopped in BW35 transmission.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture105_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture107_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture106_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture145_640_x_480.jpg)

Thought I’d start to strip other stuff out, so after a bit of a struggle managed to get the doors off.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture168_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture170_640_x_480.jpg)

The bonnet and the radiator slam panel.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture171_640_x_480.jpg)

This is the way it looked when I left for home today.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture172_640_x_480.jpg)

Very pretty little car Chris.

You think it looks pretty now ...................

We’ve done a bit more now. Managed to get the doors stripped out, window glasses, door locks and handles, winder mechanisms etc. Now the drivers side door empty weighs the same as the passenger door unstripped. So what gives??
Well on closer inspection …….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture173_640_x_480.jpg)

It appears that there’s a bit of filler in the lower part of the door.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture178_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture179_640_x_480.jpg)

Now we got all the filler out in a big pile on the floor ………………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture183_640_x_480.jpg)

I took this home and weighed it, 3.5 lbs, in one part of the door. This what was underneath ………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture184_640_x_480.jpg)

And this what the door looks like now all the crap has been removed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture188_640_x_480.jpg)

We need to do the repair on the lower part of this door before the other one is started on, because we need measurements from the other door to get this one right first.

Lovely car, so much potential.
But the filler!
Why do people do that ! Easier to repair the door properly than to fart around with that much filler.
Bought a Singer Chamois where the sills were made of rolled up newspaper and filler, must have taken weeks to do, looked so good. Only took a weekend to replace the sills properly.

Sheesh! The doors on my Pop are a bit like that, but for no reason at all. They're quite solid. Looks like someone's just skimmed the whole door to tidy them up. Odd.

its known as the ,,BOYD CODDINGTON,, treatment  :D :D :D

Hey, I wouldn't worry about it, a lot of manufacturers do it. I was surprised when I went over to Fintans (F H Ellis) one day and he was prepping a Ferrari for sale at Bonhams festival of speed auction. He was putting a skim coat all over, and I was told that this is what would have happened at the factory when they were new!!

OK, a little more today. I though I’d try and clear the engine compartment. Started out looking like this.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture190_640_x_480_zps5f259db3.jpg)

And after removing radiator side supports, lower panel under radiator, air intake for heater just below the windshield.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture195_640_x_480_zps304ec330.jpg)

Heater assembly.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture196_640_x_480_zpse77f827f.jpg)

Then disconnected wiring loom, regulator, fuse box and removed back to firewall. Removed choke cable, starter pull cable and solenoid, brake pipes and brake light switch assy. Then, removed the windshield.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture192_640_x_480_zps5de43ca2.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture193_640_x_480_zpse8a99186.jpg)

That’s it ‘till after the new year now …………….

That's very nearly empty now surely. Has the lady decided on a colour yet Chris? There was a purple & white one at the Blackbushe meet yesterday.

No, still loads to pull off, dash and the rest of the loom, headliner, rear screen glass. Then there's all the underneath stuff!!
As for colours, it's going to be the same colours as the Portafold, Old English White and Rootes Electric Blue.

Ooh, nice. Blue bottom? (not you).

White roof, blue top of body, bonnet and back, white bottom

Had another good day of solid work, still stripping bits out. Got the front wings and front panel off.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture204_640_x_480_zps0fbbfb09.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture207_640_x_480_zpsf76bde7e.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture208_640_x_480_zps456856cd.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture209_640_x_480_zpsed81baa4.jpg)

And after spending some time inside the car this is the pile of bits I ended up with.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture211_640_x_480_zps3beb3760.jpg)

Dash board, wiring loom, gear lever and linkage, steering box and column. So nothing inside now!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture215_640_x_480_zps2eee504b.jpg)

Just about had time to remove the 3 piece rear window as well.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture219_640_x_480_zps522feef3.jpg)

phunkie,
remember i said about h/gaskets ?
well iv,e got them here in front of me now ,
numbers on the end of the pack as best i can read em = A6440   2A490 x10
numbers actually on gasket =2A490
there,s 8 left in the pack made by PAYEN

is there a boot lid to this motor. ???.

 ;D No, it's not the one Loony got given last week Terry!
Metropolitans don't actually have a seperate boot.

'Cept from '59/60 to end of production in '62.

I stand corrected Sir. What year is yours?

'57. If you check out thr picture you put up, you can just see the boot lid, boot lid cars also have 1/4 light windows, whilst hard top cars have one piece rear window glass.

Learning new stuff every day!

Well, still pulling bits off
Fuel tank was next and it was nearly full, which I was to discover that the sender unit float was full of fuel and showing the tank to be empty. So people in the pas had been adding fuel thinking it was empty.
It’s also contaminated with water, so it’ll get used for cleaning!
Top side of the tank looks ok, but there is a leak on one point of the seam.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture227_640_x_480_zps70ebf049.jpg)

Underside is pretty scabby, looks like someones “repaired” a damaged part by fixing in (welded, stuck, soldered?) a square plate. Upside, it’s not leaking.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture225_640_x_480_zpsc114f792.jpg)

I’m thinking, when it comes to it I’ll fabricate and have TIGed up a replica in 2.5 or 3.0 aluminium.
This is pretty much the last of the stuff underneath, battery cable, brake pipes, master cylinders and brackets, steering idler, etc. The pedals are soaking in WD to get them apart. Other than that there’s only the front and rear axles/suspension to remove. 

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture229_640_x_480_zps580cc403.jpg)

So before the car is stripped completely and the block is sent for boring, I need to check on engine/gearbox clearance issues, if there are any.
I assembled the block, front mount plate, rear plate and the transmission together. The whole idea of this is to check clearances with new engine and gearbox mounts. The transmission that the car came with is a Borg Warner 35 box. This would not have been fitted as standard, it had a 3 speed manual column change box (not he easiest thing to master), and as Sue would prefer the auto box, it’s staying.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture232_640_x_480_zps19ba999b.jpg)

With that done the engine/transmission was slotted back in the car and bolted in. The new head rested on and the carbs as well, as this is all a strange combination for this car. The new starter, having been modified already, was bolted in and the clearances checked all round.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture239_640_x_480_zps78c89a98.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture240_640_x_480_zps384cc9ba.jpg)

Seems to be ok. Just one more thing to check is the transmission dip stick. It’s slightly too long and from the engine/trans split comes up at the wrong angle. Fitted it back on and marked where it needs to be reshaped and shortened slightly. This can be done once the unit is back out of the car.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture242_640_x_480_zps9b4ecba7.jpg)

Later

That motor really fills the engine bay well doesn't it Chris. Love the carb set up. Are those the standard manifolds? So that's a Borg Warner box on an MG engine? Some sort of adaptor needed? I know bugger all about MGs.

The manifolds were supplied with the cylinder heads as far as I know. You could get all sorts, this one is for H4 SUs (1.5"), also available H6 SUs (1.75") and side draught Webers (DCOEs).
On the exhaust side you could use the standard manifold or an aftermarket 3 branch , but we've had some flanges and stubs made from stainless, which in my opinion will look neater. A standard 3 branch from Moss would have to be modified to fit anyway

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture245_640_x_480_zps94287e27.jpg)

35 BW gearbox, when available, was fitted to most BMC/Leyland vehicles that had automatic. It's just a matter of finding the right (standard) parts to put together to make it work. Those parts are getting rarer all the time. The box is basicly the same through all applications, but the more power it needs to cope with the more plates in the cluches there will be. Pretty much the bellhousing was the difference between different applications. This one will be rebuilt using Rover V8 spec. The car arrived with an engine and gearbox from  a 1600  Morris Oxford/Austin Cambridge, so some of the parts needed were already "in stock". So it's a Borg Warner 35 box onto a "B" series BMC engine.

Just managed to secure this little gem on US eBay out of Columbus Ohio. Paid $50 for it. $50 for an old BMC 1500 engine, halfway round the world I hear you say. Well if you click on the photo to enlarge, you might jus see that it is wearing a alloy Derrington/HRG rocker cover. Rare as hens teeth (just like the cylinder heads). Bought the whole engine, but the guy's quite happy to remove just the rocker cover and ship it to our contact in New Jersey, it should be in a container leaving in just over a week. Judging by the price of the cylinder heads this has got to be worth a couple of hundred pounds (paid £41 inc shipping to NJ + a small amount of container space)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/KGrHqNlMFDkgy3DusBQ6biRqkpw60_57_640_x_480_zps39d7cef4.jpg)

Ain't t'interweb wonderful! A lucky find Chris.

Yes, it was a lucky find, it'll be really cool when it gets here!!

Right on with the bodywork, after hacking away at the obvious rust areas on the rear wings …………………………..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture254_640_x_480_zps31970cb5.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture262_640_x_480_zpse7176920.jpg)

……….it was decided to remove them. These were welded on at production and as you can no longer get them new anymore, or even 2nd hand if it comes to it, it had to be done. So very carefully the seams were cut into using a real slim dremel metal disc (took ages).
The passenger side wing removed …………..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture268_640_x_480_zps6c805790.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture267_640_x_480_zps30d0021d.jpg)

Kinda glad we did remove it now. The repairs needed to the inner arches can be carried out a lot easier, but it did show up some previous repairs that were less than ideal. These can now be corrected to a better standard.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture269_640_x_480_zps7d4dbac5.jpg)

Sheesh. Where do you start?!

Sometimes building a car is easier than rebuilding one!!

I think Manky knows that after the Charger.....................   ;)

Never again!
The Pop ain't exactly simple either.

Just a small update, ‘cos I’ve had some electronic problems with the daily (now sorted), not much has been done.
Front engine mounts, these require “shimming” to prevent premature failure. Because the origins of the plate that bolts to the engine (don’t know if it is the right depth or not) this needed to be done. It was a matter of fitting one side mounting complete, fitting the other side to the engine and measuring the gap between  that mount and the “chassis” bracket.
This measurement is divided by 2 and that is the required thickness of the two shims needed. These were made from aluminium (doesn’t matter what material, they’ll be stove enamelled to finish anyway).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture271_640_x_480_zps08c60278.jpg)

They were then assembled to the engine and front cross member. Fitted perfectly, no stress in the rubber now and therefore no vibration from that area.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture270_640_x_480_zps1050622f.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture272_640_x_480_zps68623c95.jpg)

OK, so the other side rear wing needed to be removed. Now done.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture281_640_x_480_zps368f4d77.jpg)

The paint is now being stripped, starting with the inside, notably the floor.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture288_640_x_480_zpsca77e911.jpg)

This has uncovered the holes that are needing repairs. We decided not to have the whole thing media blasted (too scared).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture290_640_x_480_zps34b4e6b6.jpg)

Managed to get the transmission filler/dipstick tube sorted, with some help from Steve (BookHimDanno on here).
It was too long and not angled up enough as can be seen here

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture284_640_x_480_zps46f51a26.jpg)

The breather was detached.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture285_640_x_480_zpsf903a3bb.jpg)

With the help of a tube bender, it was bent to a better angle. The dip stick was inserted and the projecting length measured. An amount was removed from the outer tube, internally tubed and welded. Weld was then filed, the breather cut to length, re drilled, the end sealed and the breather welded back o the outer tube. The dipstick was then inserted back into the tube and the projecting piece measured. The first measurement was subtracted from the second and the result removed from the dipstick, putting the high and low mark back exactly where it originally was. Whole thing was then trial fitted back in the gearbox.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture299_640_x_480_zps8fe5f317.jpg)

This was the last thing that was stopping the engine being sent to the machine shop to be bored, ground and balanced (it’ll be dropped off tomorrow 25th).
The rear wing and inner wing situation, as regarding rust, will now be resolved. I think they are too far gone to repair with out major surgery. I have managed to get hold of some panels from a California car, which I collected from Derbyshire yesterday. They are in real good condition for their age, so watch this space.

I was wondering how you were getting on Chris. Looking nice.

will know by next week but we may have some sills for the met

That would be cool. I've been talking to Fintan Ellis about getting some made. Need to be talking to you about the side trims as well. I'll call you next week some time.

Now we have a plan, let’s put it into action. Using square tube (1”) a bracing frame is constructed (don’t know weather we need one, but belts and braces!).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture295_640_x_480_zps0c1cdd2c.jpg)

Remove both the inner wings, roughly.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture302_640_x_480_zpsf4872a3b.jpg)

And finally remove the boot area covering.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture304_640_x_480_zps05b423fd.jpg)

Clean up the inner wing areas. These will need the parts of the inner wings, still attached, removed later.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture305_640_x_480_zpsecfe9ee7.jpg)

This is what we’ve ended up with for the supply of panels, but unfortunately ;D ::) it’s the later type with a boot lid!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture309_640_x_480_zps0f3ddffc.jpg)


I made the trip over to Luton this afternoon to the guy that brings the stuff in from the States, Russ Pepper at…..  http://www.randrhotrodimports.co.uk/  
For my latest shipment.
This little gem, quite rare, especially in this condition.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture312_640_x_480_zpsa2f91100.jpg)

The rocker cover, for the engine, is also here.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture313_640_x_480_zps2b19c9cd.jpg)

And way back in November I bought this, from a guy in Wisconsin, just in case I needed it!!  :D

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture316_640_x_480_zps044bbdb0.jpg)

More to follow …………..

Ok, so it’s been a while. I’ve been recommissioning a 1963 Morris Oxford Estate, barn find (about 40 years in the barn).
Anyway back to business, I realised that the exhaust manifold would have to be made so that it could be installed onto the engine, during reassembly, without having to damage any body or engine paint.
So back in the engine and trans goes and start to cut and tack weld the selection of stainless bends bought for the purpose. I had some flanges lazer cut and some stubs pressed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture329_640_x_480_zpsce66e978.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture329_640_x_480_zpsce66e978.jpg.html)

Using a spare big valve iron head as a jig.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture335_640_x_480_zpsf288d197.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture335_640_x_480_zpsf288d197.jpg.html)

More cutting and tacking and finally as much as I can manage with it in the car.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture339_640_x_480_zps9c6d69e5.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture339_640_x_480_zps9c6d69e5.jpg.html)

The routing of the primary pipes is so tight that they have to go down, one over the other and not side by side.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture337_640_x_480_zps6687984e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture337_640_x_480_zps6687984e.jpg.html)

Now to remove the engine/trans (this will not go back into the car until all the body and paint has been done and the engine reassembled) and finish the manifold collector and first bit of the front pipe.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture343_640_x_480_zps73667a0e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture343_640_x_480_zps73667a0e.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture350_640_x_480_zpsb2bcfa47.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture350_640_x_480_zpsb2bcfa47.jpg.html)

Now the pipes/bends are all tacked and the tacks cleaned up, I’m going to take all this lot to be TIGed up by a buddy of mine after which all the welds will be cleaned up before final assembly and polishing.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture351_640_x_480_zps72287efa.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture351_640_x_480_zps72287efa.jpg.html)

Getting replica body sills have been a bit of a task. The ones Scottie had were, unfortunately, no where near what we needed. To my good fortune, a guy in the Met owners club (Pete Whetstone) had a pair of brand new (as near as you’ll get to the originals) sill. These were not for sale but he kindly lent one side to me to get some folded up.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture331_640_x_480_zpsef563d38.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture331_640_x_480_zpsef563d38.jpg.html)

So I approached Fintan at F H Ellis ( http://www.fhellis.com/ ) to see if he could help me out. Two weeks later I came away with these basic folded pieces of metal.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture3301_640_x_480_zps25b94ff6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture3301_640_x_480_zps25b94ff6.jpg.html)

Now to start to cut and add the extra pieces required to fit.
Inner sill

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture332_640_x_480_zpse0f50e6e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture332_640_x_480_zpse0f50e6e.jpg.html)

Outer sill.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture334_640_x_480_zps3d892144.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture334_640_x_480_zps3d892144.jpg.html)  

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture333_640_x_480_zpsd2e82d86.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture333_640_x_480_zpsd2e82d86.jpg.html)

The original sill had to go back last week (met Pete at Enfield, he lives in Nuneaton) so I just tacked up one sill and now have a part finalised jig to do the job properly.
Something else I needed to do is sort the boot floor. The original has peppered holes all over it. The new rear end has a solid floor. Had to be careful not to damage any other panel that I need to use, but I’ve managed to remove it in a fairly good condition, just need to do some small repairs and a depaint and rust before fitting it.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture341_640_x_480_zps6acbdee6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture341_640_x_480_zps6acbdee6.jpg.html)

More to follow ………………….

Exhaust is looking lovely Chris.

Lot of work, but worth while in the end, I think.

holy s**t, great work.

I'd missed when you cut the back off . Excellent work as always Chris :)

Still more to cut off yet, Kev!!

So, still removing stuff, but seeing the light at the end of the tunnel for the rear end now.
Cut out roughly the boot floor. This is it next to the replacement going in.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture352_640_x_480_zps23915776.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture352_640_x_480_zps23915776.jpg.html)

Then clean up the main “chassis” members ready for the replacement floor.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture353_640_x_480_zpsca72a914.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture353_640_x_480_zpsca72a914.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture355_640_x_480_zpscb3c88da.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture355_640_x_480_zpscb3c88da.jpg.html)

There are a couple of small repairs to carry out on the ends, and doing them now will make the whole job easier.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture356_640_x_480_zps8b3c9899.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture356_640_x_480_zps8b3c9899.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture357_640_x_480_zpsa40de8f7.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture357_640_x_480_zpsa40de8f7.jpg.html)

No more for a couple of weeks now, ‘cos we’re at Beaulieu next weekend.

Now, the chassis end pieces have been replaced with good metal and the rear ½ cross member spot welded back on.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture362_640_x_480_zps7dea4b94.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture362_640_x_480_zps7dea4b94.jpg.html)

As this car may well tow our Portafold caravan, I decided to add some strength to the rear. So made an internal cross member, out of 2mm wall 2” x 1” box. To that welded some turned spacers and side link pieces.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture363_640_x_480_zps9e4f1a2b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture363_640_x_480_zps9e4f1a2b.jpg.html)

Now the ready to fit boot floor, with a coat of epoxy primer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture365_640_x_480_zps06649d74.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture365_640_x_480_zps06649d74.jpg.html)

And spot welded into position.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture366_640_x_480_zps349fde9b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture366_640_x_480_zps349fde9b.jpg.html)

And now the battery box support sides and the rear spring hanger support plate. All the inside of box sections have been painted with red oxide.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture369_640_x_480_zpsfa29a38c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture369_640_x_480_zpsfa29a38c.jpg.html)

The exhaust manifold has been welded up, sanded off and polished.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture377_640_x_480_zps3df9c37b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture377_640_x_480_zps3df9c37b.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture376_640_x_480_zpseee95d5f.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture376_640_x_480_zpseee95d5f.jpg.html)

That’s all finished now, until final assembly.
The rear end bodywork has now been cleaned of all its surplus seams and has gone of to the media blasters, should have it back next Thursday.

That 'zorst is stunning Chris!

I was thinking the same, great workmenship

Beautiful!

Thanks guys, still a loooooong way to go though.

just read this thread from the beginning... spot on, must have the patience of a saint.

No, you just need to keep focused on the end result.

Didn’t want to do anything too taxing or strenuous today (31 degrees in the end), so I decided to make an engine. This would move the project on and also get rid of the growing mountain of cardboard boxes that housed various parts.
So, start with a block that’s been checked and bored.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture379_640_x_480_zpsf4fa6025.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture379_640_x_480_zpsf4fa6025.jpg.html)

And a crank that’s been ground, polished and balanced.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture380_640_x_480_zps5c04788d.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture380_640_x_480_zps5c04788d.jpg.html)

Put them together, then add some pistons and rods.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture382_640_x_480_zps0a7bb101.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture382_640_x_480_zps0a7bb101.jpg.html) 

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture385_640_x_480_zps601254b8.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture385_640_x_480_zps601254b8.jpg.html)

Add a Piper “automatic grind” camshaft.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture386_640_x_480_zpsd46a5340.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture386_640_x_480_zpsd46a5340.jpg.html)

Bolt on a new timing chain set and tensioner.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture387_640_x_480_zps8b92eea0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture387_640_x_480_zps8b92eea0.jpg.html)

Fit an oil pump and the sump, and finally cover it all in BMC green.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture390_640_x_480_zpsf4ab75e1.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture390_640_x_480_zpsf4ab75e1.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture389_640_x_480_zpsdfe5292a.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture389_640_x_480_zpsdfe5292a.jpg.html)

‘Nother little job done!!

Just like that!  No effort at all - apparently...

Work up a little bit of a sweat, workshop's got a glass roof!!   ;)

to coin a phrase "I love it when a plan comes together"

Would be better if it was coming together a bit more quickly!!

Perfection takes time.
If you wanted it quickly perhaps you should be restoring an NSU. ;)

 :D

Just thought I’d do a bit more at lunch time. Had already got in early and put a last coat of engine paint on. On Saturday the paint was going off almost as soon as it was leaving the bristles on the brush!!
Fitted a few little bits and pieces, engine mounts, block drain tap, oil pipe to the filter, fuel pump and engine breather pipe. Fitted the distributor and timed it up using the points that were in it.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture391_640_x_480_zps1365a1e3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture391_640_x_480_zps1365a1e3.jpg.html)

Then took the points and condensor out and fitted a Pertronix kit instead.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture392_640_x_480_zps452a6cb2.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture392_640_x_480_zps452a6cb2.jpg.html)

I needed to finish off making and fitting the plug leads, so fitted the dynamo and distributor cap to get the leads the right length.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture394_640_x_480_zps6d084d90.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture394_640_x_480_zps6d084d90.jpg.html)

Whilst I was at it, I thought I’d try the exhaust manifold to see what it looked like against the new paint.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture393_640_x_480_zps760f67bc.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture393_640_x_480_zps760f67bc.jpg.html)

The head is only fitted with a couple of studs, the motor will be installed with the gearbox but without the head when the time comes. So now the engine is wrapped up and sealed until we need to install it.
The rear end bodywork comes back from the media blasters on Thursday, so I can get on with the metalwork then.

What a lovely looking thing that is Chris. Rather nice.

Trouble is, this is the easy bit, it's just nuts and bolts.

I think you need to treat yourself to an "easy bit" once in a while to keep yourself motivated through the "bloody 'ell, I'm fed up with this" bits.

You may remember this scabby old bit of rear end body work

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture309_640_x_480_zps0f3ddffc.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture309_640_x_480_zps0f3ddffc.jpg.html)

Well it came back from the blasters today, and this is what it looks like now.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture395_640_x_480_zpsc8b14480.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture395_640_x_480_zpsc8b14480.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture396_640_x_480_zpsc91466e1.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture396_640_x_480_zpsc91466e1.jpg.html)

I’ll put a coat of epoxy primer over it tomorrow.

Looks pretty solid Chris.

compared with the one that came off the car, it is very solid.

Also looks pretty straight. Is there much remedial work needed?
Are you going to use it complete or for panels for the original rear?

Few dents to straighten out, other than that it's in pretty good shape for a bit of 53 year old car. Only problem is the metal is so thick the hammer just bounces off!!  :o

OK, so just a small update.
Managed to get a coat of epoxy primer on the rear end bodywork before the rains came.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture399_640_x_480_zps2ed47a60.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture399_640_x_480_zps2ed47a60.jpg.html)

Stripped the rear end down for the parts to go to various places. The casing, brake back plates, U bolts, spring front mounts to the powder coaters. The 3rd member to the axle specialists, Hardy Engineering http://www.hardyengineering.co.uk
And the springs to Brost Forge for re arching.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture398_640_x_480_zps14f90d2b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture398_640_x_480_zps14f90d2b.jpg.html)

Thought I’d have another look at the body work. The bottom of the passenger “B” post is a real mess.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture397_640_x_480_zps6629dc8c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture397_640_x_480_zps6629dc8c.jpg.html)

Think we’ll start by putting some more bracing in and get the sills sorted before putting the rear end bodywork on finally.

Before the rains came

Rain? I'm less than 10 miles from you & not seen a drop of rain for weeks.
Progressing nicely Chris.

Apparently, yesterday in Ascot it was thunder and lightning and heavy rain for a while. It has been forecast, but obviously we've got away with it. Wasn't taking any chances.

Managed a bit more, yesterday. Added some more bracing.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture400_640_x_480_zpsdf578303.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture400_640_x_480_zpsdf578303.jpg.html)

Then started to remove the passengers side sill, Quite a mess in there.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture401_640_x_480_zpsfc12b719.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture401_640_x_480_zpsfc12b719.jpg.html)

Stripped the whole length of the sill out and did a trail fit of the new inner sill. Looks to be a good fit, just got to clean out inside the chassis an treat it before the whole sill can be fitted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture402_640_x_480_zpscd6c5bc6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture402_640_x_480_zpscd6c5bc6.jpg.html)

Looks a bit like it might have been easier to start from scratch and build new!   :o   (I know that's not the point)

No, you're probably quite right!!

Edit.
Bit more info as to why we've got to carry on. After extensive searches (at Gaydon, with other Met owners , etc. etc.)We believe that this car could be the earliest example of a RHD UK home market car left. It was built in the first full week of production and was the 12th or 13th off the line.

Well it’s been a while since I’ve been able to do some more work on this project, ‘coz of all the other stuff that’s been going on, so todays bit was a good move forward.
I’ve been try to get round to fitting the car on the rotisserie, that was fabricated for it (as I couldn’t find one to buy) for quite a while.
So at last today it’s now fitted, which will now make it a lot easier to do the repairs on the underside and inside the side chassis members.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture403_640_x_480_zps65762d5c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture403_640_x_480_zps65762d5c.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture404_640_x_480_zps074360e3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture404_640_x_480_zps074360e3.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture405_640_x_480_zpsabb705d4.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture405_640_x_480_zpsabb705d4.jpg.html)

As I say, it’ll be easier to get to these sort of bits now.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture407_640_x_480_zpse6a3c02e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture407_640_x_480_zpse6a3c02e.jpg.html)

Is it possibly the earliest Met of any kind?

Nice rotisserie.
That will save a lot of time and effort. How do you lock rotation?

No, this is not the earliest Met of any kind. The first Mets, LHD, came off the assembly line at Longbridge in 1954, destined for the US. They were a very popular small second car, but sales in the US started to diminish in'56. So Austin asked Nash/AMC weather they could make, and sell, a right hand drive version. So early in 1957 (March) production of right hand drive versions started. These were not only for our own home market, but for the colonies as well (like Australia, New Zealand, South Africa, Aden, etc.). This car was built on the 8th March 1957, which was the Friday in the first full week of production of RHD models, and far as we can see (with lots of research in the production archives) this was the 12th or 13th UK home market car off the assembly line. There were about 9000-9500 home market cars produced, when production ceased in 1962, and is believed that only about 300 of those are in existence today. I have all the preceding chassis numbers to ours and have asked in various places if any of these still exist and have, as yet, not received any correspondence to say that any exist. So our assumption is, we believe that this car is the earliest RHD UK Home market in existence.

As for the rotisserie, the locking mechanism is just out of shot, just a bar that links the lower bar of the triangle and the front mount bracket on the shell. This bar has a sequence of holes at one end so the shell can be set at differing angles using just a couple of 10mm bolts and nuts.

I really wish I'd built a rollover a long time ago, the amount of time I've spent on my back welding up chassis rails etc. It's always been  " Well ,it won't take long so no need to go to that trouble "  ::)
Excellent work as always Chris .

Found a bit of time today to take a photo.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/roto001_zpsc2835523.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/roto001_zpsc2835523.jpg.html)

So this is the really boring bit, Loads of work and things move forward very slowly.
Now we’re able to turn the car upside down it is a lot easier to do the under car repairs.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture408_640_x_480_zpscfe00063.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture408_640_x_480_zpscfe00063.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture409_640_x_480_zps4b6e98ee.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture409_640_x_480_zps4b6e98ee.jpg.html)

Took a while but they now look like this ………………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture413_640_x_480_zps91a32720.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture413_640_x_480_zps91a32720.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture412_640_x_480_zpsfe55052b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture412_640_x_480_zpsfe55052b.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture415_640_x_480_zpsbdeccdc6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture415_640_x_480_zpsbdeccdc6.jpg.html)

Finished all the major work on one side inner and outer sill

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture410_640_x_480_zps19c7ffb4.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture410_640_x_480_zps19c7ffb4.jpg.html)

Joined the two together with four tack welds.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture411_640_x_480_zpsd102255e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture411_640_x_480_zpsd102255e.jpg.html)

Then a trial fit, all is good.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture414_640_x_480_zpsd656cdde.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture414_640_x_480_zpsd656cdde.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture416_640_x_480_zps5ce51d19.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture416_640_x_480_zps5ce51d19.jpg.html)

So I now have to put the large holes in the inner sill and spot weld the inner and outer together, but more of that later.

Spot on as always mate! Andy and I will have to pop in sometime and have a nose if that's ok?

Thanks Marcus, yeh, no problem pop over and have a look see. Call me before you leave, 'cos some days I work over in Godalming (Andy's got my number). Sorry to hear that you've been poorly.

It’s kind of cool to actually start fitting bits back on after so long removing parts.
So now with the passenger side inner and outer sills fabricated, holes cut and flared in the inner sills, rust treated and red oxide primed inside ……..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture417_640_x_480_zpsc687ec96.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture417_640_x_480_zpsc687ec96.jpg.html)

They are fitted together and spot welded …….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture418_640_x_480_zpsb12c389a.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture418_640_x_480_zpsb12c389a.jpg.html)

Then assembled to the car and welded …….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture423_640_x_480_zpsc2e59684.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture423_640_x_480_zpsc2e59684.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture421_640_x_480_zps88fefec6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture421_640_x_480_zps88fefec6.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture420_640_x_480_zps278d3d13.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture420_640_x_480_zps278d3d13.jpg.html)

Once the sills were attached the lower portion of the “A” post renewed, replacing the old rusted out portion ………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture419_640_x_480_zpsd6f440e8.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture419_640_x_480_zpsd6f440e8.jpg.html)

The rear most part of the sill and the lower portion of the “B” post repair will be addressed when the rear end body work is fitted on.
With one side sill now done we need to start stripping the drivers side out.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture422_640_x_480_zps561e03c7.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture422_640_x_480_zps561e03c7.jpg.html)

There was only one jacking point on this car (passenger side). Looks pretty scabby, so we’ll remove it …..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture425_640_x_480_zps98ce03c3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture425_640_x_480_zps98ce03c3.jpg.html)

And replace with new later model jacking points …..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture424_640_x_480_zps48590d07.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture424_640_x_480_zps48590d07.jpg.html)

Getting further into removing the sill, it’s become evident that it’s been done a couple of times before!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture427_640_x_480_zps1133362f.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture427_640_x_480_zps1133362f.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture426_640_x_480_zpsdfaf2d94.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture426_640_x_480_zpsdfaf2d94.jpg.html)

Hopefully get some more done this week.

The chassis parts on the drivers side seems worse than the passenger side, for some reason.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture428_640_x_480_zps56458958.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture428_640_x_480_zps56458958.jpg.html)

So this will need to be replaced together with the front floor box section, which has an access hole to install the hand brake cable and clevis. All I had to go on, as far as the hole was concerned was these two broken bits of metal (on the right) and the bit left from the passengers side.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture434_640_x_480_zps2d203e93.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture434_640_x_480_zps2d203e93.jpg.html)

So putting the whole lot together I managed to get the right size and shape hole with a return on the inside edge.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture431_640_x_480_zps7481634c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture431_640_x_480_zps7481634c.jpg.html)

Assembled with the new “chassis” piece and the gearbox cross member it looks like this.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture429_640_x_480_zps94f61b86.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture429_640_x_480_zps94f61b86.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture430_640_x_480_zpsce374053.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture430_640_x_480_zpsce374053.jpg.html)

With all that fully welded, the other sill was required. So as not to bore you all, the sill was fabricated and constructed in the same way as the passenger side and welded on. Reconstruction of the lower portion of the drivers side “A” post was needed, and followed the same route as the other side.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture441_640_x_480_zpsd20c8e6c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture441_640_x_480_zpsd20c8e6c.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture444_640_x_480_zps8d37a019.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture444_640_x_480_zps8d37a019.jpg.html)

Now with a coat of rust inhibitor, it’s ready for some epoxy primer. I’ll get round to that in the next few days.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture445_640_x_480_zpsa238fd62.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture445_640_x_480_zpsa238fd62.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture446_640_x_480_zps2d938d37.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture446_640_x_480_zps2d938d37.jpg.html)

I have now cut away most of the “B” posts, except for the main door jamb plate (the later ones, as on the new rear end, are a different shape, as are the rear of the doors), we’ll use those to fit to the new rear end bodywork.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture437_640_x_480_zps0a2c970d.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture437_640_x_480_zps0a2c970d.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture438_640_x_480_zpse801c342.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture438_640_x_480_zpse801c342.jpg.html)

The roof returns at the rear need restoring ……

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture440_640_x_480_zps9fb6ca28.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture440_640_x_480_zps9fb6ca28.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture439_640_x_480_zpsfefcaaf6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture439_640_x_480_zpsfefcaaf6.jpg.html)

So all cleaned up and fabricated pieces welded in ….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture443_640_x_480_zps71cda7fe.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture443_640_x_480_zps71cda7fe.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture442_640_x_480_zps2c6ce6fd.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture442_640_x_480_zps2c6ce6fd.jpg.html)

That’s it for the moment, the next job will be to attach the rear end bodywork, but this needs some remedial work before the two can be joined together. That’ll be for the next update.

That really is excellent work, and a pleasure to see this "rebirth" progressing the way it is, well trousered Sir!!!!!!!!!!! I look forward to the next episode! Morrag

I wonder if it was a seaside car at any time in its life Chris ? My uncles Escort was the same far worse on one side as always parked the same way on th seafront.  Great work:)

The only two areas we can place it in for sure is, Horsington in Lincolnshire and St Austell (don't think it was there for long)

Edit
It was Hayle in 2008 (just checked the V5), so four years in Cornwall. I think there was a lot of work carried out a while back (i.e. 10 years)so it was rusting even back then.

Right, onto the rear end bodywork. Even though this came from California, it doesn’t mean that’s it is totally rust free!!
Sometime in it’s previous life, the car it belonged to got rearended. It had not been repaired very well, where another rear panel had been fitted the inner wheel arches had been lapped over each other and welded on the inside only, meaning water got under the joint and rusted them out. The bad parts were cut out and new sections added.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture447_640_x_480_zps0955af51.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture447_640_x_480_zps0955af51.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture448_640_x_480_zps256029f6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture448_640_x_480_zps256029f6.jpg.html)

New corner fillets were fabricated and welded in, enabling the lower outer wing pieces to be secured properly. I had to replace an area around the left hand rear spring hanger at the same time.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture449_640_x_480_zps341ca5a5.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture449_640_x_480_zps341ca5a5.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture450_640_x_480_zps090c84b0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture450_640_x_480_zps090c84b0.jpg.html)

The areas behind the inner wings were then sealed, usually this gap is filled using old fashioned dum dum, but I’ve used Sikoflex.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture451_640_x_480_zpse418ec5e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture451_640_x_480_zpse418ec5e.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture452_640_x_480_zpsa21e9fd3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture452_640_x_480_zpsa21e9fd3.jpg.html)

Now the rear part of the assembly is ready to go, the front part needs attention. The “B” post front skin is different from the early to the late model cars. So I need to use the two that are on the car and join the rest of the rear assy to them. I cut off the front panel, had to do this in pieces to save the structure behind.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture457_640_x_480_zps85a4639c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture457_640_x_480_zps85a4639c.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture458_640_x_480_zpse060ed4b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture458_640_x_480_zpse060ed4b.jpg.html)

Then remove the old inner sill, this was pretty mangled so I will have to make up some small repair pieces when it comes to fit this to the car.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture460_640_x_480_zps08590144.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture460_640_x_480_zps08590144.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture461_640_x_480_zpsaac16bc8.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture461_640_x_480_zpsaac16bc8.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture462_640_x_480_zps219403cf.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture462_640_x_480_zps219403cf.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture463_640_x_480_zps8b1396a5.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture463_640_x_480_zps8b1396a5.jpg.html)

That’ll do on this side for the time being, now onto the other side which is in a worse state.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture464_640_x_480_zpsb78dd3e5.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture464_640_x_480_zpsb78dd3e5.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture455_640_x_480_zpsf623748b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture455_640_x_480_zpsf623748b.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture456_640_x_480_zps4c40228e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture456_640_x_480_zps4c40228e.jpg.html)

That’s as far as I got today, some more next week maybe.

I’ve been able to spend some time this week, here and there. I chose to do something that required removing the last mechanical items from the car.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture465_640_x_480_zpsb84aecca.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture465_640_x_480_zpsb84aecca.jpg.html)

After removal ………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture466_640_x_480_zps5b0c37d2.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture466_640_x_480_zps5b0c37d2.jpg.html)

This is the set up that is being used to replace the drum brakes, a late MG Midget front disc brakes. I’ve seen quite a few of these conversions done in the States, but not here.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture467_640_x_480_zps7ae2292f.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture467_640_x_480_zps7ae2292f.jpg.html)

With the old suspension removed the next job is to fit a front anti roll bar. These little cars didn’t come with one as standard and with the soft suspension, they suffered with a bit of body roll. With a bit of research, I reckon an up rated 1500cc MG Midget bar will do the job. Their weights are pretty similar. As an aside, most of the suspension and steering used ‘50s period BMC/Austin set up together with a BMC “B” series engine.
The new “state of the art” Midget lower suspension arms were fitted, with new bushes and assembled onto the car. Drop links and brackets fitted to the lower arms and the anti roll bar fitted to the drop links.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture468_640_x_480_zps49ea1abc.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture468_640_x_480_zps49ea1abc.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture469_640_x_480_zpsa5d29545.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture469_640_x_480_zpsa5d29545.jpg.html)

A pair of brackets were fabricated to attach to the front engine mount cross member and the ARB securing brackets. With a bit more fettling these will be ready for powder coating.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture470_640_x_480_zps30901723.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture470_640_x_480_zps30901723.jpg.html)

And here we have the finished article ………..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture471_640_x_480_zps8b128048.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture471_640_x_480_zps8b128048.jpg.html) 

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture472_640_x_480_zps4ed69d5c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture472_640_x_480_zps4ed69d5c.jpg.html)

Now back to the bodywork. I’m going to attempt to fit the rear end body work at the weekend, so maybe another update then!!

Lovely work Sir!
Damned handy them using BMC components.


For some reason the idea of suitably updating a classic seems alien to some in this country. You get the "but it's not original" brigade.
No it's not, it's better and more suited to todays driving conditions.

Quite a few, you see them on eBay, having said that there's none on there at the moment.
It's the NKI ones that are rare, as few as one or two.

Well, I feel that I’ve actually achieved something today. After all the niggly little repairs to the sills, underside and the new rearend bodywork, we now have rear wings and rear panel on the car!!
This is the rear assembly ready to go ……………..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture473_640_x_480_zpsaa4673f6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture473_640_x_480_zpsaa4673f6.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture474_640_x_480_zps342c1a3d.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture474_640_x_480_zps342c1a3d.jpg.html)

And the car, with the “B” post front panels cut down, all ready to receive the rear end bodywork …………..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture475_640_x_480_zpsd9fb907f.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture475_640_x_480_zpsd9fb907f.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture476_640_x_480_zps2e3a234f.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture476_640_x_480_zps2e3a234f.jpg.html)

So still on the frame at the front and with the back floor chocked up and the rear frame removed, the bodywork was introduced using an engine crane ………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture478_640_x_480_zps58aae855.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture478_640_x_480_zps58aae855.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture479_640_x_480_zpsb4c4c375.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture479_640_x_480_zpsb4c4c375.jpg.html)

Pulled and heaved and levered  the bodywork onto the car. Welded the joints on the outside of the “B” posts and as I couldn’t get the spot welder to the inner seams, I drilled and rosette welded them.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture481_640_x_480_zps7c6b38d9.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture481_640_x_480_zps7c6b38d9.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture482_640_x_480_zps661ea3a0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture482_640_x_480_zps661ea3a0.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture480_640_x_480_zps76fcded9.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture480_640_x_480_zps76fcded9.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture485_640_x_480_zps5da7a186.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture485_640_x_480_zps5da7a186.jpg.html)

The rear seam, boot floor to rear panel, was then spot welded. After making a tool to pull the shock towers down to the boot floor, the originals were spot welded, Ive started to rosette weld through the drilled out spot welds and to weld all round the seam to the floor.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture483_640_x_480_zps27bcb104.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture483_640_x_480_zps27bcb104.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture484_640_x_480_zps83f6c4a3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture484_640_x_480_zps83f6c4a3.jpg.html)

Sorry about the last picture, bit fuzzy, I’m off for a couple of beers now and watch some nitro racing!!

Thank you, Dave

For my first five years in the trade, (read apprenticeship) I worked at BMC main agents. So what I learned then has stood me in good stead. All I'm actually doing here is using standard parts from other BMC models to upgrade handling or performance. It also works the other way round, a friend, who trials a Midget wanted a rear brake set up when he found out that on the Met they are 1" bigger in diameter than the Midget!!
Not only are the suspension and brakes BMC derived, but also the engine. All cars had  "B" series engines, early ones had a 1200cc engine then the series 2 had a 1500 engine same as A55, wolseley 1500 and 15/60, riley 1.5 etc. Then came the 1622 in the A60 etc, and then the 1800 in the MGB. All pretty much interchangeable if you know how.   ;);D
We're also using tuning stuff from the period as well, The head is stamped July 1958, the carbs are 1500 MGA as are the Vokes air filters.
As for the "but it's not original" bit, The UK Met owners club are not all purists and their aim is to see as many Mets back on the road, they're not worried weather they are standard old things or full blown tube frame V8 versions!!

I think you may have a problem getting in and out of the finished motor with all that box section welded across the door openings... :D :D :D :D :D :D :D :D.............then, what do I know, you might be very thin and built like a "racing snake"!!!!!!!!! Morrag

Bit more welding on the body and we'll be able to take some of that out

Loon & I must come over to your place & check this out Chris. Very professional looking job.

You know you're always welcome, not much to see though. Give me a call before you come just in case I'm not going to be there.


Now with the rear bodywork fully welded on

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture489_640_x_480_zpsb24e1ae1.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture489_640_x_480_zpsb24e1ae1.jpg.html)

And the “B” posts fully welded top, to the roof, and bottom, to the sill

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture488_640_x_480_zps68149f53.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture488_640_x_480_zps68149f53.jpg.html)

The fillets that hold the roof to the body can be refixed

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture487_640_x_480_zps8c322288.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture487_640_x_480_zps8c322288.jpg.html)

And also the lower parts of the inner “B” posts. I had to remove these as I couldn’t fit the rear on due to the shape of the inner sill, that they fix to

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture486_640_x_480_zps30d8099d.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture486_640_x_480_zps30d8099d.jpg.html)

Also managed to remove some of the bracing, I can get in now to make repairs on the floor

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture490_640_x_480_zps145bb777.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture490_640_x_480_zps145bb777.jpg.html)

Before I left for home today, I threw the doors in the holes to see if they still fitted. They seem ok, if a little tight at the rear, but they did fit really badly when we first got the car

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture492_640_x_480_zpse471f7c6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture492_640_x_480_zpse471f7c6.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture493_640_x_480_zpsace6018b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture493_640_x_480_zpsace6018b.jpg.html)

Some more soon.

Why it's very nearly finished!

You think?   :-\

only needs wheels an engine!!!!!! lol
outstanding work there, nice one.

Engine's on the engine stand and the wheels are in the loft!!

Had a little bit of time to spare late Monday afternoon, bit bored with bodywork, so started looking at the front suspension.
Here’s both units and the difference can obviously be seen

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture494_640_x_480_zps4d33a841.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture494_640_x_480_zps4d33a841.jpg.html)

Stripping them down, the Midget one on the left and Met one on the right

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture496_640_x_480_zps2daf094e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture496_640_x_480_zps2daf094e.jpg.html)

From the photo it can be seen that the king pins are mounted differently to each other. The Midget one is mounted to the lower arm and goes up through the swivel/spindle assy. The Met one, however is mounted to the upper arm and goes down through the swivel/spindle assy. So, we need the Midget swivel and hub, the Met king pin and upper arm. The lower arm is the same in both cases and we already have new ones of those.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture497_640_x_480_zps77e45cb0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture497_640_x_480_zps77e45cb0.jpg.html)

To enable the Midget swivel to correctly fit the Met king pin, the bushes need to be replaced. In the States they have new ones turned up out of  bronze or similar material

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/P1050540_640_x_480_zps2b412430.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/P1050540_640_x_480_zps2b412430.jpg.html)

And fitted into the swivel like this

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/NewBushingsInstalled_640_x_480_zps2a450964.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/NewBushingsInstalled_640_x_480_zps2a450964.jpg.html)

But what I discovered whilst carrying out the measurements on both swivels was that the upper bore diameter to carry the bushing was the same, and as I already have new Met bushes the top ones will fit straight in. The lower ones, however are larger, but if I remove just under 1mm out of the diameter of the old lower bush the new lower Met bush can be pressed in. I bought an adjustable parallel reamer on eBay last night, to do this job, and it should be here tomorrow. The final thing to do is ream out the new buses, but with no reamer (I have one for the Midget bushes but they’re a different size!! So as I have a second pair of Met king pins, I can use one of these to make a reamer to do the job. Just need to run an angle grinder cut the length of the king pin at an angle so that it makes a cutting edge. As new king pins aren’t available using a slightly worn pin as a reamer pays of because the king pins we’re going to use are slightly worn as well.
Some more once I done this little job!

These are the stock replacement Met king pin bushes.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture498_640_x_480_zps47c84ca6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture498_640_x_480_zps47c84ca6.jpg.html)

The top bushes needed to be modified as the grease point on the Midget swivel is in a different place due to the calliper position. So just a slot to allow the grease to get to all of the bush and king pin.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture500_640_x_480_zpsc90d8136.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture500_640_x_480_zpsc90d8136.jpg.html)

With the top bushes in the lower original bushes were reamed out to take the stock Met ones.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture499_640_x_480_zps01d69a66.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture499_640_x_480_zps01d69a66.jpg.html)  

And the lower bushes pressed in.


(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture501_640_x_480_zps0aa49018.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture501_640_x_480_zps0aa49018.jpg.html)

All in now

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture502_640_x_480_zpse4ef089c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture502_640_x_480_zpse4ef089c.jpg.html)

As the lower bush/king pin is the same diameter as the Midget one, I have a Midget king pin bush reamer, and the lead in before the cutting teeth is quite long, I installed the reamer in backwards. So just reaming the lower bush, not both.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture503_640_x_480_zpsfd3b914d.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture503_640_x_480_zpsfd3b914d.jpg.html)

Now, I haven’t got a reamer to do the top bushes, so I used an old spare king pin and cut some grooves in it.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture504_640_x_480_zps4c89cf50.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture504_640_x_480_zps4c89cf50.jpg.html)

This was then inserted right way in and after a fashion, it seemed to work. Once I’d gone right through it was still a bit tight, so I used fine valve lapping paste on the king pin (top end only) and a cordless drill attached to end threads, and effectively lapped the bush in.
So we now have a pair of rebuilt swivels ready for paint or powder coating, can’t make my mind up!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture505_640_x_480_zps97c4ec1e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture505_640_x_480_zps97c4ec1e.jpg.html)

I’ve been waiting for some shims, so the king pin end float could be set up. Now these have arrived and the king pins/spindles have the right end float, they have been trail fitted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture522_640_x_480_zpsa9cafffa.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture522_640_x_480_zpsa9cafffa.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture521_640_x_480_zpsbc9d339e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture521_640_x_480_zpsbc9d339e.jpg.html)


From these being fitted the length of the new brake hoses can be calculated. They needed to be about 1.5 inches longer with a banjo at the calliper end. I could have done this using standard BMC parts (banjo + adaptor + stock hose), but thought this might look a bit Walt Disney. So I called a buddy of mine, Guy, he works for a hydraulics company (http://www.a1hydraulics.co.uk/flexible-hoses) and they’re going to make some original style hoses the right length and with the correct ends. Meanwhile the new callipers have arrived.

Back to the body, on the footwell sides under the wing there should be a strengthening panel. This would normally be part of the windscreen posts right to the forward edge of the footwell. The drivers side has one, but too short and no closed end and the passengers side, it was missing completely.

 (http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture508_640_x_480_zps3ddd8f7f.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture508_640_x_480_zps3ddd8f7f.jpg.html)

The box shape folded up

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture509_640_x_480_zps643040b6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture509_640_x_480_zps643040b6.jpg.html)

And the end result rust treated and epoxy primed. The forward end is not exactly as original, but as strong and less likely to trap mud and dirt.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture512_640_x_480_zps04736b17.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture512_640_x_480_zps04736b17.jpg.html)

Now with the passengers “A” post pretty much finished, the drivers side was finalised. With the strength now fully back in the shell the bracing was completely removed. The small repairs in the drivers side floor (front and rear) were then addressed and that side rust treated and epoxy primed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture514_640_x_480_zps3a6296f4.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture514_640_x_480_zps3a6296f4.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture513_640_x_480_zps7548ed4b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture513_640_x_480_zps7548ed4b.jpg.html)

You are getting on with this nicely now starting to look like things are going to be taking shape very soon. Well done i am liking it.

Thanks for that Mr North.

A bit more in the bag, as it were ......

Now to the passenger side, and the same, some small repair patches and a coat of rust treatment.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture515_640_x_480_zps81e5893c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture515_640_x_480_zps81e5893c.jpg.html)

Then a coat of epoxy primer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture516_1024_x_768_zpsc29295ea.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/picture516_1024_x_768_zpsc29295ea.jpg.html)

Now the bracing has gone the rear “seat” panel can be reattached.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture517_640_x_480_zps608be8a0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/picture517_640_x_480_zps608be8a0.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture518_640_x_480_zpsd47bc595.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/picture518_640_x_480_zpsd47bc595.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture519_640_x_480_zps71e53e7e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/picture519_640_x_480_zps71e53e7e.jpg.html)

And now welded in with a coat of rust treatment.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture520_640_x_480_zpse89efa29.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/picture520_640_x_480_zpse89efa29.jpg.html)

Lookin' great Chris. Very solid. Is that a brush on primer? Looks very thick,

The rust treatment is a water consistency brush on product and the primer is an epoxy, 50/50 paint and hardener spray on product. Keeps rust away from bare metal areas. Once the whole car is covered in it I can start to repair some of the dents, just sand of the primer, repair the dent and locally spay with epoxy again. Small repairs can just be filled and shaped over the epoxy, then recoated. Once the whole car is straight, normal hi build 2K primer can be used to gain a good painting surface.

Excellent work going on in that there workshop, mate  ;D  It's great to be able to share and record all the hard work being done, as a great deal of it ends up being hidden from veiw as the projects progress. Keep up the good work.

Thanks for that Mr Mendalot

Now we need to put a coat of epoxy over the rear seat area.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture523_640_x_480_zps2ad767bc.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture523_640_x_480_zps2ad767bc.jpg.html)

The front hubs have now come back from re drilling to 5 on 4.5” and 7/16 studs.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture524_640_x_480_zps3ad94334.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture524_640_x_480_zps3ad94334.jpg.html)

Put some bearings in and fitted them up, to check out the new discs and callipers.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture526_640_x_480_zps235d0ffc.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture526_640_x_480_zps235d0ffc.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture525_640_x_480_zpsa6281dd8.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture525_640_x_480_zpsa6281dd8.jpg.html)

Only to find some issues with the bearing fit. Standard bearings for MG Midget front hubs are ball bearings, what we will be using are taper roller bearings. The ones that have been supplied us, as equivalent, have a smaller radius on the inner bearing than is on the spindle. This results in a gap, between the spindle shoulder and the face of the bearing, of about 0.020”. We could have the spindles machined with a smaller radius, but this will reduce the strength of the spindle and is likely to cause stress risers where the spindle and shoulder meet. I have heard cases where the spindle has actually snapped after carrying this mod out. So the inner ends of the inner bearings will be ground with a larger radius, which will solve the problem.

We also got some tyres on the rims now, whitewalls will be sorted out after the car has done about 1000 miles.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture527_640_x_480_zpsa6f4abae.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture527_640_x_480_zpsa6f4abae.jpg.html)

I went to remove the passengers side top spring cup, which is usually just a tight fit over a small raised spigot.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture529_640_x_480_zpsea5cc8d7.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture529_640_x_480_zpsea5cc8d7.jpg.html)


After the welds were removed and the cup turned upside down, this is what was found.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture530_640_x_480_zpsbdf6ba93.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture530_640_x_480_zpsbdf6ba93.jpg.html)

This is what it should look like (the drivers side).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture531_640_x_480_zpsb56bd5f7.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture531_640_x_480_zpsb56bd5f7.jpg.html)

Think I’ll come back to that. The panel that the steering idler is bolted to on the passenger needs a bit of a cuddle. The main bolt that holds the idler had come loose at some point, broken its captivation and also broken out the hole for the second securing bolt and nut. This had been badly repaired.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture528_640_x_480_zpsc8aaf5a5.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture528_640_x_480_zpsc8aaf5a5.jpg.html)

Once the “repair” had been removed, this is what we had to work with.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture532_640_x_480_zps2d65750f.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture532_640_x_480_zps2d65750f.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture534_640_x_480_zps62b4c6af.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture534_640_x_480_zps62b4c6af.jpg.html)

After bolting the idler on, as a guide.


(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture533_640_x_480_zps1db52aa3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture533_640_x_480_zps1db52aa3.jpg.html)

A more permanent repair was made.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture535_640_x_480_zps3696d5a6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture535_640_x_480_zps3696d5a6.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture537_640_x_480_zps91ed296e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture537_640_x_480_zps91ed296e.jpg.html)

Now turning our attention to the front of the “chassis” members, that had rotted out. These pieces contained tubes for the mounting of the front bumper irons.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture538_640_x_480_zps12cab413.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture538_640_x_480_zps12cab413.jpg.html)

The strengthening pieces were missing on both sides, so new ones were made and installed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture540_640_x_480_zps18b7965b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture540_640_x_480_zps18b7965b.jpg.html)

And then replacement outer “chassis” pieces made and installed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture541_640_x_480_zpsa8d3f5b7.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture541_640_x_480_zpsa8d3f5b7.jpg.html)

And on the other side as well.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture539_640_x_480_zpse5350e12.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture539_640_x_480_zpse5350e12.jpg.html)

At least the thing has now stopped creaking as the shell is revolved!!
Now back to that spring cup locator. Cleaned the area all round the damage and fabricated a tube set into a shaped flat plate.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture542_640_x_480_zps1d98ec45.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture542_640_x_480_zps1d98ec45.jpg.html)

And welded it in, also welding through to the gusset above, in the engine compartment.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture543_640_x_480_zps245deefc.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture543_640_x_480_zps245deefc.jpg.html)

Then a blanking arrangement at the open end of the “tube”.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture544_640_x_480_zps219f569b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture544_640_x_480_zps219f569b.jpg.html)

And the spring cup fits back on perfectly, with out having to secure it with welds!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture545_640_x_480_zpsb727e278.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture545_640_x_480_zpsb727e278.jpg.html)

Now all the repairs to the inner wheel arches are complete, a coat of rust treatment is applied. I did want to get it in primer before Christmas, but have run out of time. At least the bare metal is protected, to an extent.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture546_640_x_480_zps1f53609f.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture546_640_x_480_zps1f53609f.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture547_640_x_480_zps40194edf.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture547_640_x_480_zps40194edf.jpg.html)

Well that’s it for 2013, back on it in the new year.

Merry Christmas and a Happy New Year to all our readers.

And to you Chris & Mrs Chris.
Looking fantastic.

Right, so we’re back into it, now Christmas and our vacation is over.
The old captivation devices for door hinge screws left a little bit to be desired, so new ones were bent up.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture548_640_x_480_zpsa6c276ac.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture548_640_x_480_zpsa6c276ac.jpg.html)

And fitted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture549_640_x_480_zps9d848a72.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture549_640_x_480_zps9d848a72.jpg.html)

Thought I’d try and get the lower portions of the front of the rear wheel arches sorted with fabricated panels. I did originally have a supply for these and the front wing ones, but now the guy doesn’t seem to want to supply them.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture550_640_x_480_zpsd0dc651a.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture550_640_x_480_zpsd0dc651a.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture551_640_x_480_zps44b65b94.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture551_640_x_480_zps44b65b94.jpg.html)

After exploring different options to do this, I realised that I had spare outer sill panels and that they were the right shape (curvature) for the lower part, so I would then just have to make a bridge piece.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture552_640_x_480_zps798615f5.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture552_640_x_480_zps798615f5.jpg.html)

Then fully weld and sand the panel. Just needs a bit of fettling and some filler to complete.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture553_640_x_480_zps55e38503.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture553_640_x_480_zps55e38503.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture554_640_x_480_zpsd7bbe103.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture554_640_x_480_zpsd7bbe103.jpg.html)

outstanding work there,well done.
looking forward to more great progress

cheers chris.

Thanks Chris
Yeh, so am I!!   ;D

Well, I managed to get a couple of hours on it during the week and started fabricating the drivers side rear wheel arch front repair. Managed to finish it today, get some rust treatment on and shoot it with some epoxy primer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture556_640_x_480_zpsb901ce88.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture556_640_x_480_zpsb901ce88.jpg.html)

And the passenger side in primer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture557_640_x_480_zps96371ec1.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture557_640_x_480_zps96371ec1.jpg.html)

As today was bright, sunny and less damp than it’s been for a while, I thought I’d like to get the engine compartment and inner wings in primer, so spent a bit of time on that.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture558_640_x_480_zps4fb319f3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture558_640_x_480_zps4fb319f3.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture560_640_x_480_zps27d09fc2.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture560_640_x_480_zps27d09fc2.jpg.html)



With priming in mind, I sanded down the screen pillars, mounting edges and the area from the tops of the doors all the way from the front to the back. Rust treated and primed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture559_640_x_480_zpsd365444a.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture559_640_x_480_zpsd365444a.jpg.html)

Whilst I was sanding the guttering, there seem to be rather a lot of paint layers. So I decided to carefully sand back a bit of the paint on the roof and found 8 layers of paint, starting from the original and ending with the last time it was painted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture555_640_x_480_zps0d19a6d4.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture555_640_x_480_zps0d19a6d4.jpg.html)

As far as the shell goes there are just 3 areas to deal with now, The rear of the rain gutters, the joint on the “B” post between the roof and the post face and the area in front of the windscreen including the air duct for the heating, oh and get the paint off the roof, that'll be 4 then. Start them next week. Then we start the filling!!! :o

good work. Would you take on my doors? I can do it, but I'm a bit lethargic at the moment, no, revise that I'm just to damn lazy. Must try harder I know, and when I see all what has gone into this I feel even more lazy. Good work, love following this thread.

Thanks for that, You have a pm. There will be another update soon, we moved house a week ago Friday and we've been getting straight. I'm still spending some time on it now and then, but I'll be back on it more at weekends in the near future.

OK, so here’s a small update. We’ve been moving house, so haven’t really been able to spend normal time on the car for a month now. Will be back on it again from next weekend though.
The battery box needed some attention and I thought it best to manufacture a new one, so got Fintan Ellis to fold up, in kit form, the sides and base. Will assemble these later.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture568_640_x_480_zps84b2e8e2.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture568_640_x_480_zps84b2e8e2.jpg.html)

Next I spent some time on the brake master cylinder mounting bracket. This is a picture of the original standard mounting bracket.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture563_640_x_480_zps81bdc941.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture563_640_x_480_zps81bdc941.jpg.html)

Looks plenty flimsy to me, so using some of the spare threaded holes in the chassis at that point, I made a strengthening bracket that could be removed should a purist ever own the car in the future!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture564_640_x_480_zps4097acf0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture564_640_x_480_zps4097acf0.jpg.html)

This will be powder coated before final fitting.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture565_640_x_480_zps0b09b99a.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture565_640_x_480_zps0b09b99a.jpg.html)

Whilst working on the brake pedal area, I made sure the pedal lined up with the hole in the firewall, it didn’t before.
I needed to get started on the steering column, so fitted it into the car with some of the accessories fitted (heater, brake pedal, wiper motor) and marked out the column.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture561_640_x_480_zps3c24e964.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture561_640_x_480_zps3c24e964.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture562_640_x_480_zps427fa99d.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture562_640_x_480_zps427fa99d.jpg.html)

Removed it and fabricated a jig.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture569_640_x_480_zps8df51e96.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture569_640_x_480_zps8df51e96.jpg.html)

What follows is a number of pictures, in sequence of a power steering addition using manufactured new parts from start to trial fit.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture570_640_x_480_zpsc88a5cf0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture570_640_x_480_zpsc88a5cf0.jpg.html) 

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture567_640_x_480_zps85a1a708.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture567_640_x_480_zps85a1a708.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture571_640_x_480_zps54608d0a.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture571_640_x_480_zps54608d0a.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture572_640_x_480_zps1c9965f4.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture572_640_x_480_zps1c9965f4.jpg.html)

You’ll notice that even the original gear shift mechanism still fits in it original position and it functions perfectly. I will however need to fabricate a plate to fit under the wiper motor, which needs repositioning by about half an inch.

More later.

Is that the Vauxhall Corsa power column Chris?

Maybe    ;)

I won't repeat the pictures but nice steering conversion Chris :)

It's more than likely going to have a complete closing in panel under the dash to the top of the toe board, so you won't see it at all.

Just a small update. Having removed the steering column and assembled it together permanently, refitted it back into the car and fabricated a couple of brackets to secure it (doesn’t really need it, because it is assembled as a complete unit). This is a picture taken from about half way up the window part of the “B” post and all that can be seen is a part of the motor and the torque sensor.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture573_640_x_480_zps80e4fd0e.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture573_640_x_480_zps80e4fd0e.jpg.html)

As I mentioned before the wiper motor requires moving a small amount to clear the EPS motor. Just needed to make an adaptor plate to reposition.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture574_640_x_480_zpse6bdb810.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture574_640_x_480_zpse6bdb810.jpg.html)

Then fit it to the motor …………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture575_640_x_480_zpse7757597.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture575_640_x_480_zpse7757597.jpg.html)

And the whole assembly to the car.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture576_640_x_480_zpsa1df3abf.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture576_640_x_480_zpsa1df3abf.jpg.html)

Back to bodywork next week, to finish of the shell.

Very tidy Chris.

Thanks Andy

I managed to find a couple of hours today, so I took some seam cappings that Fintan Ellis folded up for us …………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture577_640_x_480_zpsc05d544d.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture577_640_x_480_zpsc05d544d.jpg.html)

These fit over some of the spot welded seams to make them look tidier and seal the seam from water ingress. First was the seam across the rear between the rear panel and the boot floor cross member.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture578_640_x_480_zps02f69575.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture578_640_x_480_zps02f69575.jpg.html)

Then the seams above the front footwells.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture579_640_x_480_zps4b1be348.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture579_640_x_480_zps4b1be348.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture580_640_x_480_zps3fbe17c9.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture580_640_x_480_zps3fbe17c9.jpg.html)

These will be seam sealed and undersealed later.
One job I’ve been avoiding is the air intake box for the heater blower

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture581_640_x_480_zpsad8ba0f1.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture581_640_x_480_zpsad8ba0f1.jpg.html)

Every time I’ve looked at it I couldn’t figure out what to do with it., so taking the bull by the horns I carefully drilled out all the spot welds that held it to the body and removed it.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture582_640_x_480_zps9fd4a9e0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture582_640_x_480_zps9fd4a9e0.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture583_640_x_480_zpse159fcd7.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture583_640_x_480_zpse159fcd7.jpg.html)

As you can see, it needs a bit of a cuddle. So carefully drilling out the spot welds, we ended up with three separate pieces which can now be blasted before reassembling and refitting.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture584_640_x_480_zpsfc891326.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture584_640_x_480_zpsfc891326.jpg.html)

Is there a drainage hole in that intake Chris? I've got the dashboard out of my Pop at the moment, & discovered the cowl vent, which ducts air to the screen demisters, had half an inch of water in the bottom.

If you look at the second to last picture, of the assembled box.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture583_640_x_480_zpse159fcd7.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture583_640_x_480_zpse159fcd7.jpg.html)

 You'll see that it has two half inch drain tubes onto which hoses are fitted. These drain out into the lower engine compartment.

Ahh, yeah, I was thinking along those lines for mine.

Haven’t been able to do too much since the last update, but the heater blower plenum has now been sand blasted, reassembled, rust treated and epoxy primed. Now ready to be re welded back into the car.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture585_640_x_480_zps4c73c409.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture585_640_x_480_zps4c73c409.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture586_640_x_480_zpsfd0902e2.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture586_640_x_480_zpsfd0902e2.jpg.html)

Managed to find a bit of time to take the doors to the media blasters this afternoon, should have them back next week sometime.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture587_640_x_480_zpse72ee895.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture587_640_x_480_zpse72ee895.jpg.html)

Some great work going on here sir...can I ask you where did you buy the wheels from ?

They're a retro stateside wheel, Steve, first around in the early '60s called Radir. Available from here .... http://www.radirwheels.com/

Our particular ones are Tri ribs and were purchased through the European Radir agent, who also bring in our US ebay purchases ... http://www.randrhotrodimports.co.uk/

We also have them on our '32 roadster and on our airstream camping trailer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture197_640_x_480.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/Airsteam%20trailer/picture197_640_x_480.jpg.html)

Cheers kind sir..I know the company from old..they look so cool on your rides..guess il have to start saving for some now.. :D

wow, love that trailer, well in fact love the whole rig, gotta get my arse in gear, flog the kit and get on a rod build ::)

I did a build up thread a while ago for the trailer .....  http://www.mankymonkeymotors.co.uk/forum/index.php?topic=11211.0

Managed to do a little more this weekend. The panel in front of the front screen required some attention, so with the repairs done, the heater blower plenum welded back in and some rust treatment, the area was shot with epoxy primer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture588_640_x_480_zpsbd1604e6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture588_640_x_480_zpsbd1604e6.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture589_640_x_480_zpsa5d4ff14.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture589_640_x_480_zpsa5d4ff14.jpg.html)

I also made some wiring/pipe securing tabs. A lot of the original ones were broken, rust and repeated attaching pipes/wiring looms make them weak. So they’re just little tabs of metal with a hole at one end to be rosette welded on

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture590_640_x_480_zps320970c4.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture590_640_x_480_zps320970c4.jpg.html)

I thought that while I was collecting the doors from the media blasters, next week, I’d drop some more bits off to be depainted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture591_640_x_480_zps80d7633b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture591_640_x_480_zps80d7633b.jpg.html)

I managed, this week, to take some pictures of the rear most part of the roof gutters, (on the car that I’m using for reference) so that I know how to finish ours off. More than likely be done next weekend.

What's the big hole in the middle of the bulkhead Chris? Heater?

Yes, it is, but it doubles up, together with the hole where the spare wheel carrier is bolted, to enable the body to be mounted on a "spit" for ease of dipping the body in its many coating/paint processes.

Not long 'til Wheelsday Chris :) ;)

Didn't say which one though   ;D

Oh, and we're giving Whiff a chance to get motivated for the interior!!   :o

Well, not much happening that makes it look like it’s moving forward. This weekend I’ve done a total parts inventory, we’ve pretty much got all the big parts, but some of the smaller parts need sourcing.
Last week, I managed to get the battery box assembled and welded. As this is a bolt in part, it can be fitted later.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture592_640_x_480_zps0f7cd44d.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture592_640_x_480_zps0f7cd44d.jpg.html)

And at last the new rear hubs have arrived, together with the re drilled brake drums. The original hub is to the left at the back. The new ones will enable us to fit those lovely 5 stud Radirs.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture593_640_x_480_zps45a7a11b.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture593_640_x_480_zps45a7a11b.jpg.html)

Ooh, shiney stuff! Shiney stuff is always good.  8)

Beautiful!

Thanks guys

Had a little bit of time to do a couple of bits yesterday.
As we’ve taken the clutch pedal out, something had to take its place on the shaft. To add some strength into the pedal shaft area I made this,

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture594_640_x_480_zpsbc0b4727.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture594_640_x_480_zpsbc0b4727.jpg.html)

Which fits in like this.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture595_640_x_480_zpse3dd9281.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture595_640_x_480_zpse3dd9281.jpg.html)

Also collected the doors from the blasters (dropped some more bits off)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture596_640_x_480_zpsadbc30b9.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture596_640_x_480_zpsadbc30b9.jpg.html)

And gave them a couple of coats of epoxy primer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture597_640_x_480_zps1f032bbf.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture597_640_x_480_zps1f032bbf.jpg.html)

Neat idea . Spacer and steady bracket.
No nasty surprises with the doors then. :)

Nicely engineered Sir, but what has become the expected norm. for this particular build, as I'm sure everyone will agree.A good mate of mine had a very nice "Met." back in 1961, we used to take our girlfriends out in it! very "shiney" it was too, and quite spectacular back in the day, and it must have had something a bit special as that girlfriend, well she's still trying to get me out of the workshop!! :D :D :D :D :D..............Morrag

Thanks, as I've said before all the modifications I'm making are all bolt on, so that if (heaven forbid) a purist ends up buying it (after we've finished playing with it), they can return it back to original with no cutting and grinding.
Now the doors, well I didn't think there were (apart from the first 2" at the bottom), but there are areas of small holes (about 1/16") and evidence of filling over the top. Must have been a belts and braces way of making sure the bondo didn't fall off   :o ;).

Thanks Morrag, this one will be shiney one day!!

Got a couple more things sorted this weekend. The gearbox is due to go away to be rebuilt, after Easter. This particular generation of BW35 box doesn’t have an oil cooler and as we’re likely to tow the Portafold, we need one. The fitment is quite easy, After the sump and valve body is removed the casing is drilled in the right place (there are two bosses cast into the casing) and tapped the right thread for the adaptors to be screwed into. I have another box (out of a Stag) which I removed the cooler pipe from the front pump to the front adaptor and fitted it to the “Met” box, fitted the valve body and sump back. Then test fitted the new cooler pipes (managed to find a company on the net that makes sets of brand new Rover V8/BW35 trans cooler pipes).

 (http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture598_640_x_480_zps05b108f3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture598_640_x_480_zps05b108f3.jpg.html)

Today I started to fit doors. After refurbishing the hinges with new pivot pins and fitting them to the drivers door, the door was fitted to the body shell. After a bit of shimming we’ve got to the best position for the moment, still got to carry out the patch repair all along the bottom, so still a bit floppy.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture599_640_x_480_zps587d94a3.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture599_640_x_480_zps587d94a3.jpg.html)

Good to see the body with doors on -suddenly looks like a car!
Chris, can you PM me the details for the cooler pipes please. I've got heavy duty rubber pipes on mine, but they've chafed on the front axle.

Done.   :)

Well haven’t got a lot done this weekend. Wheels day Friday and family stuff to do today and Monday. Not too much done Saturday with all the visitors to the shop, one, Charlie Turner, all the way from Cape Town. He’s an English guy who moved out to the Western Cape and runs, with his partner, a guest house, check it out here …… http://www.thecoachhouse.co.za/
He has a couple of classics, including a Met convertible (picture’s not too good, but you get the idea)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/img001_640_x_480_zps0af49708.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/img001_640_x_480_zps0af49708.jpg.html)


The radio set up that we’ve bought for the car enables the controls to fit where the originals did (very wide fitting), but is fully electronic (including controls) has Bluetooth and USB sockets for Ipod & memory stick.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture600_640_x_480_zps5f65a574.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture600_640_x_480_zps5f65a574.jpg.html)

The original radio was complete with a mono speaker in the centre (bit like an early portable radio) and a louvred grille to cover it.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture601_640_x_480_zps22a4cc32.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture601_640_x_480_zps22a4cc32.jpg.html)

It would be impossible to fit the radio in the original place and be able to use the buttons. We worked out that if the louvers were cut out, the radio together with a small panel to hold the USB sockets would fit.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture602_640_x_480_zpsd11cd5da.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture602_640_x_480_zpsd11cd5da.jpg.html)

But it would have to stay that way when not in use. With a little more thought and a sliding tray under the radio unit powered by a small motor, it could be made to retract. So now we’re looking for another but complete speaker grille to use as a flap/cover. This is where Charlie came in. He had just re installed and original radio  (updated to FM) and had to replace part of the dash where two gauges had been fitted. For this he had bought, from the states, a small part of a dash. He used what he needed from the dash piece which left the louvred grille untouched. And this is what he bought me from South Africa.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture603_640_x_480_zpsbc7ca6ec.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture603_640_x_480_zpsbc7ca6ec.jpg.html)

So keeping the raised portion, round the outside, intact, I cut the grille out and shaped the corners.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture604_640_x_480_zps64448a9c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture604_640_x_480_zps64448a9c.jpg.html)

And now in front of our dash …….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture605_640_x_480_zpsec513168.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture605_640_x_480_zpsec513168.jpg.html)

And finally positioned where it will be fitted. All I have to do now is build the operating mechanism for the radio tray/slide and the grille panel.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture606_640_x_480_zps21555a45.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture606_640_x_480_zps21555a45.jpg.html)

So I did get something done this week, even if it was a small item, we’re still moving forward. And I wouldn’t have been able to do this without Charlies help,thank you. This is becoming a global car now!!

That's a hell of a favour -nipping over from South Africa!
Your radio sounds like something from Mr Bond's Aston.  :)

Sorry it’s been so long coming, but now I have all the major project, customer cars out of the workshop I can do a bit more to this little project!!
Needed to find something smallish to do in the couple of days leading up to our holiday, which we’ve just come back from.
Easiest, in terms of reasonably quick to do was the front/grille panel. I haven’t got any pictures of it on its own, but it has been media blasted and there are a number of issues that have surfaced.
Both ends are in need of attention, so we’ll start with the left side.
This is what we’ve started with ………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpslzlimatv.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpslzlimatv.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsg0qw9hnz.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsg0qw9hnz.jpg.html)

The return has been removed and a two inch strengthening piece spot welded all the way down, a new return fabricated and welded on.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zps78msrx4v.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zps78msrx4v.jpg.html)

Showing the final cleaned up portion, with half side light hole cut.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/010_640_x_480_zps4jcdfwft.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/010_640_x_480_zps4jcdfwft.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/009_640_x_480_zpsrmickbjy.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/009_640_x_480_zpsrmickbjy.jpg.html)

Now to the other side, which is a bit more difficult.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zps86yu0cqp.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zps86yu0cqp.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zps86yu0cqp.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zps86yu0cqp.jpg.html)

I cut this piece off.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpshtjbsvh2.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpshtjbsvh2.jpg.html)

And added a two inch strip behind as with the left side.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zps98q1vtk5.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zps98q1vtk5.jpg.html)

Then a piece over the top.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpso42b1jsk.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpso42b1jsk.jpg.html)

Finally welded on the new fabricated return.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/007_640_x_480_zpswhzbuphg.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/007_640_x_480_zpswhzbuphg.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zps2olttugm.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zps2olttugm.jpg.html)

Fabricate new upper part/headlamp lower ¼ section, joggle fitted as opposed to the original that had only 9 spots of braze holding it from top bottom! All the bare metal bits were painted with rust inhibitor.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zpsdhte51g4.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zpsdhte51g4.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/009_640_x_480_zpsojhoyk6u.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/009_640_x_480_zpsojhoyk6u.jpg.html)

Finally a coat of epoxy primer to protect it.
I still have some work to do on this, capping of the bits next to the head lamp potion and some hammer work on the dented bits.
After removing the rotisserie front portion, the front panel and the panel behind were fitted. This is needed to be done to enable the wings to be offered up.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpsrunxjq27.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpsrunxjq27.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpsslgk5p3x.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpsslgk5p3x.jpg.html)

Nice to see you today Chris & good to see you're still working on this.

Yeh, good to catch up today, Andy.

Great to see some more progress on the Met.  :)

It's good to get back on it!!

I’m still managing to fid small bits to do, between customer jobs. Here’s another small job that needed doing at some point.
The gearbox cross member is rusty, bent and has been repaired before.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zps6y5kntp4.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zps6y5kntp4.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsuuwmrsl6.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsuuwmrsl6.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsqbaounwz.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsqbaounwz.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zps5ypicojk.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zps5ypicojk.jpg.html)

You can get new ones of these but they’re around the £200 mark!! First thing to do is to remove the damaged parts.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zpsxcckcv1m.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zpsxcckcv1m.jpg.html)

Then fabricate some new repair panels.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/007_640_x_480_zpsuht1tx8a.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/007_640_x_480_zpsuht1tx8a.jpg.html)

Then the original part to the blasters, to get rid of the rust.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpsqib56oex.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpsqib56oex.jpg.html)

Fit and weld on one end.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpsmrz19zsl.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpsmrz19zsl.jpg.html)

And clean up the welds.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsvyml42hv.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsvyml42hv.jpg.html)

And with the other end on, it’s complete and ready to have powder coated.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsoe0pngce.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsoe0pngce.jpg.html)

Good as new.  :)

Yeh, and it only cost me 10 quid for the blasting and some time  ;D

Had a spare hour or so today. Started out bolting in some of the super structure around the radiator area, so I could fit a couple of front wings on.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpskkeejybz.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpskkeejybz.jpg.html)

Then took the doors off and sorted out the best wings to fit. I had the original ones off the car, but I also bought a pair from eBay a while ago. The eBay right wing was better than the original, looks like it had  been replaced, as the metal is really thick and there are no holes for the Met script on the side.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsiypos63r.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsiypos63r.jpg.html)

It topped up that the left wing that came off the car was better than the eBay one, again it looked like it had been replaced sometime in its life.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsrnprvfcd.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsrnprvfcd.jpg.html)

The white area is filler and paint. When it was blasted, they were having hastles removing this, so I had it back and am sanding it off with a grinder. Once the filler’s all gone, the wing is repaired and the dents are gone, I’ll take both wings back and have them lightly reblasted.
The wings line up remarkably well, with identical door hole sizes and they sit at pretty much the same height to the tops, so not too much adjusting to be done!!
This is how it looks from the front now.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zpsvnikovcf.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zpsvnikovcf.jpg.html)

Why, it's very nearly finished!

You think?

Sorry it’s been a while, but sorting the wings out have been a bit of a nightmare. The left hand wing had issues around the headlamp and down the front to the lower edge.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsg90arj6a.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsg90arj6a.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsw9s7bltv.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsw9s7bltv.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpsriq9tngt.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpsriq9tngt.jpg.html)

Loads of work, with two and three compound curves running down the front. I’m not going to show the jigsaw of new metal that has gone into this wing, but suffice to say it is now serviceable and solid.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsa2gj6hnc.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsa2gj6hnc.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zps3k82wzxd.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zps3k82wzxd.jpg.html)

The right hand side is a bit more of a puzzle. It fits really well at the back and to the inner wing, but at the front, around the indicator the shape is all wrong. Looks like the bumper has been forced into the wing, cutting it.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsys1esvbt.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsys1esvbt.jpg.html)

The gap under the headlamp is a concern.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zpsdt0nwnxz.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zpsdt0nwnxz.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zps4v2ighzc.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zps4v2ighzc.jpg.html)

Need to consider my options here, might be a while!!

Looking at the stuff you have done in the past and your handiwork on this project I'm sure you will sort it

Yeh, eventually!!  ;D
Here's another bit that needed sorting

Meanwhile, there are other things going on in the back ground. Small bits that will eventually need addressing. One of which is the air filters.
A while ago I bought a pair of Option air filters for an MGA. These are from the ‘50s and were made just round the corner from here at Vokes filters at Normandy (nr Guildford).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpsdimy3w36.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpsdimy3w36.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsnta7vqog.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsnta7vqog.jpg.html)

When I bought the carbs, they came with a pair of ‘50s/’60s bell mouths.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsbsn63yta.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsbsn63yta.jpg.html)

These would not fit over the fixings for the filters.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/007_640_x_480_zpsn2s60ytl.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/007_640_x_480_zpsn2s60ytl.jpg.html)

So some careful modifying of the bell mouths.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zpsvv2m0isu.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zpsvv2m0isu.jpg.html)

Allowed them to slip over the fixings.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zpsddpqgahi.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zpsddpqgahi.jpg.html)

However using the filter elements that came with the filters would have maybe caused a reduction in air flow into the carbs.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zpsaajiryds.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zpsaajiryds.jpg.html)

So some threaded bosses were turned up, to add another 1” of air gap/filter thickness to the filter element.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/009_640_x_480_zpsovtzjdq1.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/009_640_x_480_zpsovtzjdq1.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/010_640_x_480_zpsa4hvisry.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/010_640_x_480_zpsa4hvisry.jpg.html)

I now have some thicker K & N filters on the way, which will work well. Just got to source some period looking expanded steel sheet the fabricate the “grilles that go round the filter elements.

One other thing the I had been mulling over for a while now is the bonnet mascot.
There was an accessory mascot available in the late ‘50s early ‘60s. This was in the shape of the mascot that was standard on the ‘53/’54 Nash Rambler.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/Sunning_by_MSJames_640_x_480_zpsfdjogqf0.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/Sunning_by_MSJames_640_x_480_zpsfdjogqf0.jpg.html)

I think that this particular mascot looks to “heavy” for the car, so we chose the mascot from a ‘55 Rambler instead.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/SuperStock_4093-6227_640_x_480_zpsmndkfzs2.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/SuperStock_4093-6227_640_x_480_zpsmndkfzs2.jpg.html)

To me the whole thing looks lighter and more sleek.
So we bought one off US eBay. These couple of pictures aren’t the actual one, but are in a similar condition with pretty bad pitting.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/T2eC16dHJFoE9nh6pi5WBQGtH6gHNw60_3_640_x_480_zpslixyyrgt.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/T2eC16dHJFoE9nh6pi5WBQGtH6gHNw60_3_640_x_480_zpslixyyrgt.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/woman204_640_x_480_zpsqwoioyjg.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/woman204_640_x_480_zpsqwoioyjg.jpg.html)

I was still concerned about the physical size of the mascot and how it didn’t seem to be in “scale” with the rest of the car!
I did some calculations and discovered that the Metropolitan is about 25% smaller than the Rambler. To put that into context, we need the mascot to be 25% smaller.
So I made some enquiries around a few companies that dealt with 3D scanning and printing (can you see where this is going).
Sometime before Easter I took the old mascot into CDG in Alton for them to work their magic. So to scan it, remove all the pitting, reduce it by 25% and print it out into a plastic “mascot” that we can use to get it cast up by the use of lost wax investment casting.
This is what they sent me, by email, about a week and a half ago ……….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/Holes2_zpsvf3cn70w.png) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/Holes2_zpsvf3cn70w.png.html)

Just got to wait now, for the phone call to say it’s ready for collection!!

Wow !  Moern  technology eh ?

Yeh, does come at a cost though   :o

I'll bet. Though it does save having to sculpt a smaller version by hand.
Any idea where you will be getting it cast ?

I've done the search on the internet, Dave, and have a few choices. There's one at Lymington, one at Southampton, one at Lasham and another somewhere close. Popped round to one in Lasham on my way home last night, but they were closed, so I'll try Monday. I've got a couple of other bits to do but they just need to be pushed in the sand box as models and cast straight from that.

After a bit of thought about the right hand front wing below the head lamp, I decided to cut the corresponding piece from the original wing and weld it into the new one.
Remember I had bought another pair of wings and am now using the best two out of four. I didn’t really want to use any parts from these, as they might be of use to someone else in the future, still needs must.
So, I’ve cut the part I need out of the old wing.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zpsopnvnaby.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zpsopnvnaby.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpsutslbivl.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpsutslbivl.jpg.html)

Welded a new return on it, around the side lamp area.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpsmzaxhknb.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpsmzaxhknb.jpg.html)

This is the area I need to replace.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zps2mmdsufr.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zps2mmdsufr.jpg.html)

Marked out and cut about ¾” inside the fixing line, joggled the edge so that the “new” part fits level.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpso7kemxx2.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpso7kemxx2.jpg.html)

Made holes, in the “new” panel, for rosette welding into the wing.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsitr8aebg.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsitr8aebg.jpg.html)

Clamped on and welded, welds cleaned up and this is what it looks like now.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/009_640_x_480_zpsj0dxor2c.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/009_640_x_480_zpsj0dxor2c.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zpsl1kdjmna.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zpsl1kdjmna.jpg.html)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/007_640_x_480_zpsqnq9o6hh.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/007_640_x_480_zpsqnq9o6hh.jpg.html)

You can also see how far out from the panel line the repair patch is on the valence part of the wing.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zpstuvc6qam.jpg) (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zpstuvc6qam.jpg.html)

Back with some more soon.

Any progress on this ? 8)

A little bit, but not worth posting. Customer work keeps getting in the way!! Scottie just dropped me off a Triumph Herald convertible, part built, with a Sprintex supercharged Rover V8, five speed and Jag front and rear suspension. To be finished and IVAd!!

So are these paying jobs or love jobs ?

It say's customer work, so that'll be paying jobs then!!

Duh ! Next time I shall read it twice.. ::)

Chris
Any recommendations for the casting company that will do mascots etc?

Depends what metal you want your item to be cast in, Mark. If it's ally, there's a company down in Lymington that can probably help or if it can be bronze or bronze alloy, there's a company at Lasham.

has there been any more progress on this????

stix

I'm afraid not.
 Got really busy at work, then we decided to sell the roadster and buy something we could get straight in a drive and do events with. We ended up buying a 1957 MG Magnette ZB (this was last August) that had been restored but had a tired engine and box. An easy fix, or we thought so. Found that were some major anomalies that needed to be fixed, in other areas. Just doing it piece meal as we're using it and building another engine for it, to be installed over the winter. Engine's not dissimilar to the one for the Met, but will have a blower and fuel injection on a modern version of the Derrington cylinder head.
I will get back on it when time permits. Looked at it the other day and it hasn't deteriorated at all while it's been sitting there!!

Thanks for the reply,I had just re-read the whole thread and am waiting to see the finished car as no doubt you are, it's funny how a new car with just a couple of little jobs can turn into a bit of a marathon, best of luck with the magnette but we do like pics ya knows ;D
Stix

Saw a very nice Metropolitan on the M4 near Bridgend in S Wales today.Morrag

I might know who that is. Possibly the Met owners contact for the DVLA.

Tell me about it :(

But you can rebuild Capris with your eyes closed Kev. ::)