Manky Monkey Motors

Been feeling guilty about not contributing to the site, so thought that I would share some of the things that I make. This particular project is the rebuilding of a series 2 Dutton Phaeton...... rebuilding Paul's way :o  In the past I have shown links to the rebuild post which is on another site , so sorry if some of you have seen some of this stuff before, if not I hope you enjoy.  Where ever I can make something from scratch or modify something to fit my purpose, I do.

Handbrake Lever

The original handbrake lever was mounted underneath the dash and was a mismatch of old parts and so the whole lot joined the junk pile.  I got hold of a BMW Mini handbrake assembly purely because I liked the grip ;)  everything apart from the lever and ratchet plate joined the junk pile. Strangely enough the fiberglass seating tub had a place molded into it for a hand brake lever but was never used.
Cutting up some steel plate, I made the body for the lever, perfectly fit the molding, make and weld on some fixing bosses, modify the cable fixing on the end of the lever and give it all a coat of black paint, we now have a custom hand brake lever.

To make it all neat and tidy a trim panel was required to cover the workings, this was made from 1.5mm aluminium plate and covered in the same vinyl as the dash and centre console.

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i never thought that i would miss my duttons but i do,, and the dutton,,ning,, wont accept my login no more ..must have upset  one of them  ::) ::) ::)

Oooh, a new project thread to read  :)
Tidy handbrake mount. Details make all the difference don't they.

I quite see why you liked the grip, too!

Nice work and good pictures, nice to see how it was made and the end fit.

Andy

PS I enjoyed my Phaeton is was V6, black, all very exciting at 22.   

The Dash and Scuttle

The dash on the S2 Phaeton, being a flat angled panel, is just plain boring!  It also forms part of the dash scuttle to which the screen fits on to.
The scuttle is usually riveted onto the chassis rails as a permanent fixture, but in my mind I wanted to make it removable in order to easily gain access to the electrics and pedal box etc. So the SP on this part of the project :- make a removable scuttle with a more modern looking dash.

I started by cutting off the old dashboard facia, then extended the scuttle to form a surround for the new dash. Using 8mm plywood for the extension, cuttting some rebates with my trusty old pillar drill and a milling cutter, these were then bonded to the scuttle with CT1 adhesive and sanded to make the radius follow through from the fiberglass. A couple of small bits of wood glued on, make it look like the side rails also follow through. Then splosh some filler over all the joints and sand. When given a coat of primer, the scuttle didn’t look half bad.
For the dash board I have used some Alupanel which is primarily used in the sign business, comprising of two sheets of 0.03mm aluminium sheet, sandwiching a polythene core with an over all thickness of 3.5mm. The centre console is made from plywood and again using the Alupanel for the centre.

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Oooh nice.

That turned out well.

Next job was to modify the scuttle for a screen de-mister, this was done using vents purchased from Car Builder Solutions (CBS) and some old drain pipe as a plenum. I cut the pipe in half and glassed it onto the under side of the scuttle, with the inlet positioned just to the left of the heater motor so a short length of flexible pipe can drop down vertically and clip onto the heater with a 90 degree elbow.

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Will you need a de mister for the screen in this one ? As for the drain pipe,reminds me of the time my mate made some side pipes for his Anglia using plastic drain pipe.. :'( looked good for a while  :D ) he also made some bubble arches from chicken wire and paper mâché ..he.he..and two back wheels ( making 4 on the back axle ) he couldn't afford much those days..oh joyous times..

De mister is always handy just in case the interior gets a dowsing of rain, cos when the soft top goes on it turns into the tropics inside

The scuttle will be fixed on with some custom side clamps made from cut down 2mm steel angle, taking advantage of a friend who had access to a laser cutter the model name was cut into them and then off to the chromers ……. Well pleased with the result.
My first attempt at covering the dash surrounds and centre console with vinyl went better than expected, I used a spray contact adhesive used on coach dash boards so it should stay put in the sun.
The black felt tip mark you see as an arc on the dash board is my line of site from the driving position.

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That's luvverly.

Congratulations on your attempts to create a thing of beauty from a sows ear...
One day, perhaps we'll all appreciate the lines of a phaeton, time and fasion can achieve anything, the workmanship and craft youve put into this is impressive however. Look forward to seeing the finished article.

Very tidy indeed. Well done that man.
Never been keen on most kit cars, but I apreciate the work that folk put into making them special.

Thanks for the kind comments.

The humble Dutton is often a subject of much amusement between folk, not surprising given that the majority were built on a shoestring budget and the basic kit from the factory left a whole lot to be desired engineering wise.
From a personal point of view, out of all the Severnesque type kit cars, I have always liked the shape of the early Phaeton S1 and S2’s. I think the rear end is the best looking and it has the advantage of a boot.
So I set myself a target to rebuild the Phaeton into a quality car, and along the way addressing all the engineering points that people seemed to complain about, whilst keeping the car looking predominantly as it was in the brochure ……. So at the end it is still a Dutton Phaeton S2, but refined…… and a little faster ;D

Coming next, the custom floor mounted pedal box build…….. 

Here's one for Stinky ........  I needed a bigger hole in the top of my fuel tank ;)

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Was never any good at school apart from in two departments, the dining room .... I could eat for Britain ::) and the metalwork department. 40 years later and I still love making things, and am never happier, than when I can use some of the old tools I have collected over the years.
For this bit of the project I obviously got to play on the lathe, but also got to have a play with the dividing head and an old set of leather hole punching pliers that are ideal for making holes in cork gaskets ;D
The up turned thread inserts sitting on the ring that I cut out  have sealer on them and are drying before being inserted.

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Nice. Is that a tool on the left in the 2nd to last photo? Don't recognise it.

hole punchin pliers

No, they're in the 2nd photo from the top Mike, (& a nice set they are too).

That would be a riv nut tool. A very handy bit of kit.

A Rivnut tool indeed. This tool is made in England and supplied by a company called Memfast  ( memfast.co.uk )  This type of tool gives you more control when fitting the insert, in as much as the threaded section of the insert will remain in the centre of the hole, where as the pliers type can crimp the insert at an angle. 

Ahh, never used one.

4th picture then ,,

Yeah, 2nd from the bottom.  :P

Holes n punching tools and rivnuts..heaven..

The Pedal Box

Due to the seating position on these cars, I have always thought that a floor mounted pedal box would be more comfortable to use. After looking at the various ones available on the market, and getting a shock at the prices, I decided to have a crack at making one.
As with the dash scuttle, it would be easily removable as a complete unit in case of any repairs needed in the future, as working in the foot wells of these cars is not easy for a bloke of my size.
I am using a tandem master cylinder from a Fiat Tipo which had the correct bore size for my brake set up along with a cable clutch for the type 9 gear box. The throttle cable was made by modifying a clutch cable from a Honda lawnmower. The return springs were from an old pedal box in the junk pile. I have made the pedal pads adjustable.
The completed unit slips in from the foot well with the master cylinder and cables attached and is bolted in place with six M6 bolts.

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That's a nice set-up.

Beautifully made sir.
 Agree about the pedal action. Not completely happy with my pendulum setup, so may follow your excellent example.

Finally finished my custom wiring loom and electrical installation today. Ready for MOT at the end of March ;D

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Looks very neat and tidy, although I do wonder at todays auto-electrical requirements, when remembering the first '60's Mini I owned only had 2 fuses, in total!! ??? ??? ??? ??? ???.......Morrag

That's the same junction board I have in my truck, (under the passenger seat). I didn't wire mine, (Terry T did, with amendments to the dashboard by Olds). I admire those who practice the wiring black art. Nicely done Sir.

Very neat sir. As is everything you have done on this vehicle. Good luck for March.

Agree about the complexity of modern vehicle wiring. My Jag has five fuse boxes with 78 fuses and 39 relays ! Three fuses and one relay (indicators) are all I'm planning. Though this means sourcing period switches etc. as modern stuff isn't designed to take the loads.

Be careful of the sva Olds, there's a good reason modern cars went to rocker switches.

great work, but one thing.

slow down please, your all building and finishing far too quickly!!!!!   lol.

Don't worry -I'm bringing the average down by being really slow & inefficient with mine.

After a 7 year 10 month nuts and bolts restoration ......... we is read for MOT ;D      ( and you thought that you were taking a long time Andy!! )

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 :) very, very nice.

There is much satisfaction to be had by going back to basics ....... I needed a square end on a round shaft, so it was out with the files and a tub of elbow grease   Whoooo Hooooo,  happy days ;D
Nothing to do with cars I'm afraid, but it does have a wheel .......  my new BBQ is taking shape,

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That's a full-on hog roast, not just a barbeque!
Love the name -my welder's called Ol' Sparky. That's a cool wheel. Did you make it yourself?

The wheel came from ebay, complete with woodworm holes :D  it was off an old water valve.  The shaft will have pair of pulleys on for cables to raise and lower the grill. 

Well, now having fitted some doors on the workshop big enough to get the car out, It saw daylight for the first time today.

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Looks great out in the sun.

I think you've actually managed to polish a tuurd.
And done a very good job of it too.

 ;D Fabulous!

Very nice Sir!!

I love that..  it's beautiful

What are the wheels from?

Thank you all for the comments, most kind.    The wheels are Ford Mondeo ST24's

As a fellow Duttonette ! just have to say that I have followed this build on anther forum, the result of this build is superb and has raised the bar of fellow Dutton owners/builders to a high level. Mine is about to be rebuilt over the next winter period, which is about July to July  ;D. and I hope to get close to this build quality, well done Paul, I'm a bit envious  ;) Looking forward to seeing it in the flesh so to speak. Final note...........Whats Next??

Not a fan of the Dutton but that looks great and the effort put into it shows. Well done sir.

So basically he's driving a shiny poo ? :o

Well I dont know about  'polished turds' or 'shiny poo's'  but can verify that it goes like the proverbial   'Sh1t off a shovel'   ;D ;D ;D ;D  Happy days.

 ;D

The Monkey got published !!!    Hey Stinky ....... Not bad for a polished turd!  ;D ;D ;D

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Well done sir...hope it makes you smile  8)

Congratulations! Can we have your autograph? :)

Well done, you do wonder whether a decent colour paint job would have sold many more of these in the day?
Perhaps plain orange/red/green or whatever else they came in was just a bit lacking. Whatever, your creation is impressive.