Manky Monkey Motors

Technical Section => HotRod Tech => Topic started by: Manky Monkey on February 25, 2007, 09:16:11 PM



Title: Manky's Pop.
Post by: Manky Monkey on February 25, 2007, 09:16:11 PM
Actually, it's not a Pop, it's an Anglia -& so is Shaun's.
Thanks to Tazet, Ska Man & Loony for spending the day on the road with me today. We trundled down to Rochester in Kent & collected my new toy. Tazzie managed to borrow the biggest trailer in the World from her boss, along with a mate's V8 Discovery to tow it with. Neil, the Ebay selling chappie was very helpful & genuinely pleased it was going to someone who'll, (hopefully), actually do something with it.
Didn't take long to load it on the trailer -might've been even quicker if I'd helped! Well, someone had to record the event for prosperity  :D
It's now temporarily living in the trailer at Tazet's place until garage space becomes available & I've decided what to do with it.
Where the hell do I start?


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 25, 2007, 09:16:50 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 25, 2007, 09:17:31 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 25, 2007, 09:18:25 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 25, 2007, 09:19:19 PM
.


Title: Re: Manky's Pop.
Post by: spanners on February 25, 2007, 09:27:59 PM
lots of pushing and shuvving m+m not in sight bet he loves it when a plan comes together  ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 25, 2007, 09:32:59 PM
They're just making it look hard work. Looked easy to me from my vantage point on the other side of the road. It was rolling slightly downhill & literally took 2 minutes to run it straight up into the trailer. There was a winch but it wasn't needed. A Pop in a box.


Title: Re: Manky's Pop.
Post by: brock on February 26, 2007, 01:25:28 AM
Any idea what the gas rams on the trailer door are off of ?


Title: Re: Manky's Pop.
Post by: spanners on February 26, 2007, 01:36:31 AM
you can get them any size or strenth i used to fit a lot of them on luggage doors and engine flaps on coaches


Title: Re: Manky's Pop.
Post by: spanners on February 26, 2007, 01:50:29 AM
just rememberd gas struts used to come from  transervex at liverpool or st helens


Title: Re: Manky's Pop.
Post by: tazet on February 26, 2007, 07:14:00 AM
Most horse box builders sell them. I will look around and let you know as I need one for the lorry awning as one has broken.


Title: Re: Manky's Pop.
Post by: spanners on February 26, 2007, 07:29:41 AM
how far north do you go with the horses  do you do county shows


Title: Re: Manky's Pop.
Post by: tazet on February 26, 2007, 07:36:10 AM
We go all over and not so much the county chows as thats the poncy stuff but we do the equivalent to ridden 3 day eventing but in a carriage. I will do a write up one day to explain what I do (will bore most people though).
Last year I drove out to Portugal but mainly we stay in England. This year the first show is Brighton and at some point in Aug we go to Cumbria then straight on to Scotland so will be gone for about 2 weeks.

The trailer in the pic takes all the carriages and feed and equipment needed.


Title: Re: Manky's Pop.
Post by: spanners on February 26, 2007, 07:41:10 AM
andy willhave get the pop a garage then because he wont rod it that quick ;D


Title: Re: Manky's Pop.
Post by: tazet on February 26, 2007, 07:54:11 AM
Its going to Lunatics place or his garage whichever is cleared first  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on February 26, 2007, 07:10:04 PM
Really good to meet you all, especially Tazet  :-*.... one bottle gone already :-\ ;) ;D :-*.
Good to bounce some ideas around ;D ;D ;D


Title: Re: Manky's Pop.
Post by: tazet on February 26, 2007, 07:12:17 PM
Thats ok mate. The bottles were just collecting dust here, Good to meet you both too.


Title: Re: Manky's Pop.
Post by: panthershaun on February 26, 2007, 07:13:19 PM
You gotta crack the whip now ;D trike and Pop done by the summer ;D ;D ;D


Title: Re: Manky's Pop.
Post by: tazet on February 26, 2007, 07:15:29 PM
Well as the Pop is at mine I suppose I could make a start but where  ??? (we must stop calling it a Pop)  Will try and get that light off for you for Sunday.


Title: Re: Manky's Pop.
Post by: panthershaun on February 26, 2007, 07:18:54 PM
Sorry "Anglia" :-[ :-[ :-[


Title: Re: Manky's Pop.
Post by: tazet on February 26, 2007, 07:20:31 PM
Think Pop will stay. Habbit.  ;D and less letters to type  ::)


Title: Re: Manky's Pop.
Post by: panthershaun on February 26, 2007, 07:23:03 PM
Couple of sites for ya Andy

http://www.thepopshop.org.uk/notindex.html

http://www.poppartsplus.co.uk


Title: Re: Manky's Pop.
Post by: panthershaun on February 26, 2007, 07:31:09 PM
and another,
http://www.flatheadv8.freeserve.co.uk/martsframes.htm

On the index page, right hand side under the Heading "My scrapbook pictures"
you will see a heading Pop Project, check that out for a Pop build, step by step. Only no roof chop.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 26, 2007, 09:46:37 PM
Err, "especially Tazet"?  >:(


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 26, 2007, 09:47:47 PM
Could I have a say in my Pop project too please.


Title: Re: Manky's Pop.
Post by: tazet on February 26, 2007, 09:49:36 PM
Go for it as my ideas are rubbish.


Title: Re: Manky's Pop.
Post by: BikerGran on February 27, 2007, 12:46:51 AM
You're only allowed a say when you've finished the trike!

 :P


Title: Re: Manky's Pop.
Post by: panthershaun on February 27, 2007, 08:03:33 AM
Err, "especially Tazet"?  >:(

Well she did come armed with Champers ;D ;D ;D ;D ;D but it was a real pleasure to finally meet all of you, makes the forum all the more friendly to be able to put a face to a name ;D :-* :-* :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 27, 2007, 09:55:21 AM
At least we'll be able to recognise each other at the swapmeet on Sunday now!
Back to working on the trike today Bobbi, honest.


Title: Re: Manky's Pop.
Post by: spanners on February 27, 2007, 10:01:51 AM
come on andy and tazet  give the anglia a good name  POP is what i used to call my grandad  he didnt look that nice   how about  ,,angie,,


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 27, 2007, 10:04:56 AM
I'm sure it'll get called lots of things once I start working on it!


Title: Re: Manky's Pop.
Post by: brock on February 27, 2007, 07:27:11 PM
    just to side track this for a moment, I am talking to a manufacturer about gas rams and getting estimates of around 150 for a bespoke pair , anyone have a feeling for prices on the really heavy duty commercial ones ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 27, 2007, 10:06:45 PM
Trike will come first. promise.
There's a V8 Rover engined Pop on Ebay at the moment. Viva front axle, narrowed Zephyr rear, fibreglass flip front etc.
A tad more than Shaun & I paid for ours though. 2 & a half grand at the moment. reserve not met.

http://cgi.ebay.co.uk/ford-pop-sit-up-and-beg-hot-rod-no-swap-swap_W0QQitemZ120091345828QQihZ002QQcategoryZ29755QQrdZ1QQcmdZViewItem


Title: Re: Manky's Pop.
Post by: panthershaun on February 28, 2007, 07:46:00 PM
to flash by half :-X :-X needs less paint and no wings ;D ;D ;D


Title: Re: Manky's Pop.
Post by: tazet on March 01, 2007, 07:32:14 AM
I agree with the less paint but I like the wings.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 01, 2007, 02:52:45 PM
Owwww, I still can't decide if I want wings or not!
Reading the new issue of Ol Skool Rodz at the moment & must admit beat up fenderless rods do look pretty cool.


Title: Re: Manky's Pop.
Post by: panthershaun on March 01, 2007, 10:01:56 PM
no no and no :-\ too many trad style Pops around, need more stripped down, bare bones cars about ;D ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on March 02, 2007, 07:32:32 PM
This is the ONLY way to go ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on March 02, 2007, 08:57:26 PM
Youve just proved my point ;) too many fendered Pops around already :-\ :-\ ;D ::)


Title: Re: Manky's Pop.
Post by: panthershaun on March 03, 2007, 05:28:57 PM
Not sure where the pics came from, just keep surfing the net for Pop related articles.

Andy, had my Builder guru mate round today ;D had some cracking ideas for the Pop.
He has persuaded me not to get the Pop on the road for the summer but to do the job properly, as filling the roof will interfere with the roof chop etc. He is going to give me a hand doing the roof chop and pickup conversion.

Had some radical ideas for a salt lake style Pop, ladder bars and coil overs on the back, front axle pushed forward and fitted on a "suicide" perch making the whole car sit very low, radical roof chop, weld up the passenger door and run an open pipe from the engine down the passenger side about half way up the door.
2 tone paint and moonies on the wheels. What do you think?? ;D ;D


Title: Re: Manky's Pop.
Post by: ska-man2 on March 04, 2007, 01:09:58 AM
That sounds good to me, but you may have a problem getting it M.O.Td with the passenger door welded up, unless you take the passenger seat out.



                                                  Nige


Title: Re: Manky's Pop.
Post by: panthershaun on March 04, 2007, 08:57:25 AM
Could always run the pipe lower, and split the door so you have to step over a sill to get in?? The bugger has me undecided now >:( >:( but still leaning towards a pickup ::) ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 04, 2007, 09:10:07 PM
I want a pick up too, but keep getting told I'm not allowed to cut up my Pop cos it's too good. Mine's nicer than his!  ;D
I really like this pale fern green. Would make a nice change from black if suitably "aged".


Title: Re: Manky's Pop.
Post by: Dave_postie on March 05, 2007, 04:42:35 PM
you can have matching rod and trike ? janie postie and i have now got matching consuls. Yep i finally passed my driving test 1st time on thursday last week, so i brought another mk 11. Needs some work but a 2 owner car for 200 , i couldn t refuse. sorry manky but you had brought the anglia when i got emailed the pic s and a mate arranged getting it within days. Trouble is i fancy an open top hot rod for the summer, now where s that wining lotto ticket. ;D ;D ;D


Title: Re: Manky's Pop.
Post by: tazet on March 05, 2007, 05:05:15 PM
Well done Dave.  ;D


Title: Re: Manky's Pop.
Post by: Dave_postie on March 05, 2007, 05:21:54 PM
thanks tazet, I drove a reliant for about 6 years to ferry my german sheppard[ziggy] about,[now passed away but not forgotton]. everyone said dont worry, but i was still a bag of nerve s on the day. Now i wished id done it years ago but if i had id be even more skint than i am now ! ;D


Title: Re: Manky's Pop.
Post by: tazet on March 05, 2007, 05:24:04 PM
I hate exams too, but the main thing is you passed. So where did you go for your first drive afterwards  ;D


Title: Re: Manky's Pop.
Post by: Dave_postie on March 05, 2007, 05:34:52 PM
went to janie's mum and dad's[jacko] and had chocolate cake. Now if every exam/test was rewarded with choccy cake id have a pilot/hgv/helicopter licence by now. Instead ive got bike/car and tv licence, and no cake! but a figure that looks like ive hed all the cakes. ;D


Title: Re: Manky's Pop.
Post by: tazet on March 05, 2007, 05:37:02 PM
 ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 05, 2007, 07:00:03 PM
I haven't got a TV licence. Mind you, I haven't got a TV either.
Well done Dave. About bloomin' time! Hurry up & post some pics of Betty Blue, the new addition to your Consul collection. Hope we'll get another write up for the site? Or some techy articles on any restoration work you do? I guess your contribution to the MMMotors calendar could feature both cars in one photo, with a portrait shot of Janie & you together.
Hmm, you want an open top rod? I just happen to have a '27 T bodyshell & chassis going spare. Step into my office & we'll discuss it.


Title: Re: Manky's Pop.
Post by: harley gazz on March 06, 2007, 07:21:38 PM
NO TV MR MANKEY  :o :o :o mind you i suppose your always in the garage working on your trike ;D ;D ;D ;D ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 07, 2007, 07:56:05 AM
Nope, I haven't endured Eastenders, pop idiot, I'm a Z list nobody get me a career, or any other televisual delights for a couple of years now -& don't miss them at all. Not entirely sure where all my free time goes, but don't honestly think I'd have half an hour spare these days to switch on & tune out.
I watch films & box sets of the better TV series on my PC & listen to radio2, radio 7, rockabilly radio etc online too, so not entirely cut off from the outside world. Just a bit more selective about what I view.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 23, 2007, 10:29:24 PM
And here the Pop begins.  ;D
Heavy duty Sherpa van arse end.


Title: Re: Manky's Pop.
Post by: lunatic on March 24, 2007, 11:05:40 AM
I know Im jumping the gun a bit here, but I like this colour!


Title: Re: Manky's Pop.
Post by: brock on March 24, 2007, 11:25:58 AM
It'll be that colour before it's finished. Shame that '36 is blocking the view.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2007, 11:33:50 AM
 ;D
I like that -the green, not the rust. Got enough of that already. Pops came in a very pale fern green, which I really like. A matt version of that would be nice.


Title: Re: Manky's Pop.
Post by: brock on March 24, 2007, 11:39:19 AM
   there was a similar shade used by Morris which we are toying with using on the new race car ( but not for some time yet )


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2007, 11:42:06 AM
This colour.


Title: Re: Manky's Pop.
Post by: lunatic on March 24, 2007, 11:46:23 AM
Was talking to the paintshop guys the other day and they said they can do my 2 pack lacquer in satin and matt. Also they can do red oxide in all sorts of colours including mettallics! Not just red! ;) So you can get almost any paint in satin or matt finishes that will last for ages. Not like primers.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2007, 11:49:51 PM
A suggestion from Brock.


Title: Re: Manky's Pop.
Post by: panthershaun on March 24, 2007, 11:57:09 PM
Oh yes but with a pickup back ;D got a turbo on its way to me, gonna fit it to the 100e motor at first and when that has blown fit the suzuki jeep lump and turbo that :P :P :P :-\ :-*


Title: Re: Manky's Pop.
Post by: lunatic on March 26, 2007, 07:51:49 PM
Just a little scribble I did.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 29, 2007, 09:14:36 PM
My Sherpa van front beam axle, with it's disc brakes.
The steering box was buggered so I'll fit either Lunatic's spare VW one or a Reliant one, (anyone got a spare?)
In the background is one of the 15" black taxi cab wheels I'll be fitting.


Title: Re: Manky's Pop.
Post by: panthershaun on March 30, 2007, 08:10:58 AM
You can get brand new Landy boxes complete with steering column for 125.00, or I do know of a Land Rover breakers near me, could ask for you?


Title: Re: Manky's Pop.
Post by: reliantman on March 30, 2007, 08:17:40 AM
I have a piggy steering box here, off a Rialto I just scrapped.
If you could get over here you can have it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 31, 2007, 08:34:11 AM
Yeah, I've looked at Landy boxes on Ebay for similar prices, but been told they're quite big & clunky, plus that's a big chunk of my building budget. Didn't realise that price included the column too though.
Loony's got a VW box but I haven't seen it yet.
Any idea what the postage might be on your box RM?


Title: Re: Manky's Pop.
Post by: reliantman on March 31, 2007, 04:29:37 PM
Dunno, it's small but quite a lump. I will be cutting up the body in the next day or two and will unbolt & weigh the thing for you.


Title: Re: Manky's Pop.
Post by: panthershaun on March 31, 2007, 04:41:47 PM
righto, with my Postman Pat head on, Standard Parcels can go up to 20kg's @ 12.46 but check with the local postoffice as sometimes it is cheaper to send a Heavyish article by Special Delivery :o I know it sounds mad but it's true ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 31, 2007, 09:50:49 PM
Finally brought my Pop home to Basingstoke today. It's been living in a horsebox at Tazet's workplace in Guildford for the last few weeks while I cleared some garage space for it.
Opened the bonnet for the first time -well, lifted it off cos there's no hinges. Guess what -a steering box.
Brock's looking for a box for his new race car though, so may well be able to make use of the Reliant one RM.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 31, 2007, 10:04:19 PM
So with a little help from Ska Man, (thanks Nige), Tazet & I unloaded my Pop from it's temporary horsey home this morning & rolled it straight into the garage, stopping briefly to take a couple of snaps.
My 16 inch black taxi cab wheels, (unfortunately the white band tyres are perished beyond use), propped in place to see what they'd look like. Not sure whether to go with these or stick with the original Pop ones & have them banded to create wider rims if necessary. I like the tall skinny look of "proper" 50s hotrod wheels though.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 31, 2007, 10:06:19 PM
The bottom of the masking tape line would be roughly the height of the windows after a 4 inch roofchop.


Title: Re: Manky's Pop.
Post by: deegee on April 01, 2007, 03:35:10 PM
 :o Hope you're going to re-jig the doors before cutting. ;D

As to the wheels, I would say keep the front original and band the rears.


Title: Re: Manky's Pop.
Post by: panthershaun on April 01, 2007, 05:54:10 PM
Ripped my Pop to pieces today, found some rot around its rear :-[ so I don't feel to bad about cutting the rear off. If you need anything from a saloon Andy its yours mate.


Title: Re: Manky's Pop.
Post by: panthershaun on April 01, 2007, 05:55:56 PM
with that stance, you gotta go Gasser mate ;)


Title: Re: Manky's Pop.
Post by: BikerGran on April 01, 2007, 09:09:28 PM
I quite like the Pop wheels - I think it's the white on the tyres that makes tho others look so much better. I guess you could stripe any tyre with tyre paint if you got a steady hand...


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2007, 10:25:55 PM
Rear & side window glass would be good if you're not using it Shaun. I haven't got any at all.
Janie & Dave Posties visited on Sunday & we took another look at the Pop. I think I'm gonna run it more or less as it is for the time being -box the chassis, chuck in Dave's spare 1700 cc Consul engine with it's column shift box, (which'll mean pushing the front seats back a little), throw out the rear seat & run with the original two tatty brown leather front ones, the bakerlite dash I picked up at the NSRA swapmeet & as little else as I can get away with for the MOT. No interior panels, no carpet or headlining etc. Just the bare minimum to drive it. Some small satin black cycle guards over the tall skinny original Pop wheels, then blow the body over in pale Ford fern green with the MMMotors logo in black outline on the bootlid.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2007, 10:27:03 PM
.


Title: Re: Manky's Pop.
Post by: spanners on April 02, 2007, 10:34:14 PM
its a good job youve got another engine some one's nicked the one out of the pop ;D ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on April 02, 2007, 10:39:16 PM
Rear and side window glass is yours, do you want the rear panels (in nice burgandy) ?
What about the rear wings???


Title: Re: Manky's Pop.
Post by: deegee on April 03, 2007, 06:58:02 AM
Nice looking Enfield.


Title: Re: Manky's Pop.
Post by: reliantman on April 03, 2007, 09:09:15 AM
I will try and rip the steering box off this week. Was going to do it the weekend but I was forced to do housework instead  :'(


Title: Re: Manky's Pop.
Post by: Dave_postie on April 03, 2007, 01:58:51 PM
housework on a weekend, weekends are for tinkering and eating cake, hang on!i do that in the week aswell, explains why its messyin here. ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 03, 2007, 02:09:29 PM
Afternoon David.  ;)
The Enfield's Janie's pride & joy -& one of the few bikes she can actually reach the ground on.
Lovely, lovely Dave here's got a spare mark 2 Consul motor which I hope to snaffle for the Pop. It'd be great to keep it as period-correct as I can, but I'll be bunging in the Sherpa front beam axle with it's disc brakes, cos I'd like to stop occasionally.
Dave's also got another Consul rear axle so that'll be going in too. That's 5 or 6 inches wider than the Pop set up, so I might try & get the rear wheels banded with extra inset so they come inboard over the axle, then run cycle guards front & back.
I'd like to keep the interior to just the two "distressed" brown leather Pop seats -no other interior panels. Keep it as stripped down as possible.
Makes sense to drive it for a while first before cutting the body up. Much easier to cut a roof or back end than try to weld it back together! 


Title: Re: Manky's Pop.
Post by: lunatic on April 03, 2007, 02:43:54 PM
Keep it simple like the old hotrods. If it does'nt make you go faster, it goes in the bin! ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 03, 2007, 02:48:23 PM
Yup. I'll allow myself the luxury of glass though.
Yeah, I know -I'm a wimp.


Title: Re: Manky's Pop.
Post by: lunatic on April 03, 2007, 02:52:40 PM
Goggles! You wimp! ;D


Title: Re: Manky's Pop.
Post by: panthershaun on April 03, 2007, 07:41:38 PM
To be honest Andy, you could probably have all my glass as I'm going to need new for my roof chop. Stick with the Pop front axle and fit either early Ford disc's or Triumph Spitfire/Herald front discs which is what I'm gonna do on mine.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 03, 2007, 10:52:29 PM
If you really don't want the glass then of course I'll relieve you of it Sir. Thank you.
Dave says Consul motors are quite heavy so I think I'd rather go with the beefier Sherpa beam & some decent sized Sherpa discs.
The idea of a stripped down but basically untouched bodyshell is growing on me. More of a hillbilly Pop than a hotrod one.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 15, 2007, 06:06:57 PM
We were at the Farnham classic car show today & got chatting to a couple with a Pop. They were still running the original sidevalve engine but plan to drop a Rover in at some point.
They'd fitted VW wheels. I knew they fitted but have never seen them "on". I like these. Maybe coloured rims with the chrome hubcaps?


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 15, 2007, 06:08:30 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 15, 2007, 10:30:09 PM
Flap & Manky discuss the important issue of hats.
Full roof height means you can wear a big hat. There's room for a decent top hat in there. Or one of those huge furry lumberjack jobbies that look like your wearing a dead cat on your head.
A 4 inch chop means it'd have to be a trilby. A bowler hat at the most.
Radical chopping requires a flat cap -& probably a flat top haircut too.


Title: Re: Manky's Pop.
Post by: ByzMax on April 16, 2007, 01:19:42 PM
Manky if you want some VW beetle wheels I have loads including a complete set of gt wheels with new tyres on. The paint needs stripping off but might be useful.


Let me know if you  want em. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 16, 2007, 09:34:09 PM
Hi Byz, yup, I'm interested. I love the ultra skinny front Pop wheels with their square profile cross-plys, but they'd probably be scary to drive with. Beetle rims would give me a better choice of tyres, plus I'd like slightly wider rear rims anyway.
Can't decide what colours to go with. If I were keeping the Pop black, I'd paint the wheels in a pastel green. The car's going to be green though. Maybe chrome rims with matching green hubcaps? Can't afford chrome so It'd probably be metallic silver powder coat on the rims.
What do GT wheels look like?


Title: Re: Manky's Pop.
Post by: ByzMax on April 16, 2007, 11:13:47 PM
I don't have a pick on the PC at the mo but will take one tomorrow and put it up here.


I have some standard wheels and some weller style chrome jobs too will post some pics of them too


Title: Re: Manky's Pop.
Post by: panthershaun on April 17, 2007, 09:53:09 AM
The early Beetle wheels fit onto the Pop hubs, but if you are changing axles Andy that will become irrelevant unless you are going to make up adapters to take the Pop stud pattern. You already have 16" taxi rims that will fit onto the front axle, also 14 or 15" Sherpa rims if you kept them? that sorts out the front, that just leaves the rear end..

A stripped down "Hillbilly" pop sounds cool, but please don't put its arse in the air, if anything run it level and low ;D but that is just a personal thing on my part as all Pop's seem to have the same stance ::)


Title: Re: Manky's Pop.
Post by: panthershaun on April 17, 2007, 10:01:02 AM
I'm going 3" chop with mine, subtle but will change the look of the car. anything more than that and I think you then have to start looking at things like channeling the body etc the get the look right.

This guy has chosen to channel the body rather than go for a roof chop.

Have you thought about pushing the front axle forwards on a suicide perch like this one? also lowering the back end as well so the whole thing site several inches lower but level?


Title: Re: Manky's Pop.
Post by: panthershaun on April 17, 2007, 10:03:49 AM
couple more


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2007, 10:07:30 AM
Don't worry Shaun -tastefully tatty's the way to go I think. Definitely level & probably lower due to the weight of the Consul engine. Depends how high the Sherpa front beam sits really.
I've still got 4 taxi wheels -a pair of 15s & a pair of 16s, but I like the slotted Pop rims. Taxi ones are just plain. I think I've got a piccie of them somewhere. Hang on, I'll go & have a rummage ...

Here we go.
Pop wheels.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2007, 10:08:16 AM
Taxi wheels.


Title: Re: Manky's Pop.
Post by: panthershaun on April 17, 2007, 10:12:14 AM
you can buy brand new 15-14" VW wheels in 2 widths for around 40.00. I know what you mean about the nice look of the Pop wheels.
What do you think of the PrePop then??


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2007, 10:19:52 AM
I don't want to go too blingy so chrome wheels probably aren't the look I'm after. Painted would be more in keeping with the basic look, (O.K, powder-coated). I like the idea of re-cycling older stuff rather than buying new -but by the time they're coated they'll probably cost me more!
The Prefect-Pop's the channelled one? Can't decide. I prefer the Pop rad shell I think. The more I sit in mine the more I'm convinced to keep the bodyshell more or less standard, but dropping it over the chassis rails shouldn't be a major problem. Brock says I should push the front wheels forward with a perch poking through the rad surround. Not sure I like the look of the wheels that far forward though.
I think I'll end up taking the body off, setting up the rolling chassis with the Consul motor, box & rear axle & Sherpa front beam, then dropping the body on again & cutting to suit.
Let me know when it's convenient to come & pinch the glass & stuff from you matey. 


Title: Re: Manky's Pop.
Post by: panthershaun on April 17, 2007, 10:29:24 AM
Anytime really Andy, if you are coming in the week I will leave it under the Pop's cover. Busy for the next couple of weeks shooting vehicles for the mag, but I am around Sat afternoon from 1ish to around 5 when I've got to get ready to go out for a meal with some friends (yes I do have some real one's ;)) if you want to "POP" over then, let me know and I will get some cake and diet "Pop" in ;D ;D ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2007, 10:44:27 AM
Probably during the week's best. I'll let you know a day.


Title: Re: Manky's Pop.
Post by: lunatic on April 17, 2007, 05:11:17 PM
I belive the wheels Byzmax has are 4 stud for later Vws. In wide 5 stud you have the option of solid 14"(bus) and 15" x 4.5" or slotted in 15x4.5" or 15x5.5. Early beetles and buses (early 50's) had 16x4.5" rims which I might use on my v-rod. I really like the look of tall crossplies, they will probably handle terribly though!


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 18, 2007, 08:58:17 AM
Looks like it'll be the 15 x 4.5s on the front & 15 x 5.5s on the back then. Not desperately important yet cos the trike build's taking priority. The Pop's my Summer tinkering project.


Title: Re: Manky's Pop.
Post by: ByzMax on April 18, 2007, 03:12:51 PM
Manky, as stated these are four stud ones so are no good for your pop rod!

If see any around I will let you know


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 18, 2007, 10:10:36 PM
O.K Byz.
Tazet & I were passing Valley Gas Speed Shop in Newbury today, on our way home from dropping some trike engine parts off at the powder coaters. We called in as one of my mates has started working there.
Out back they've got a Pop. They plan to fit a big block Chevy motor & a 9 inch Ford rear axle. Should be interesting.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 18, 2007, 10:12:41 PM
Inside the workshop, among others, were these two beauties. 


Title: Re: Manky's Pop.
Post by: brock on April 19, 2007, 08:05:28 PM
have a look at the steering box on the Pop , is that the standard one ? pun intended.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2007, 10:06:40 PM
Yup. Well, it's the same as mine anyway.


Title: Re: Manky's Pop.
Post by: panthershaun on April 20, 2007, 09:38:57 PM
looks like mine as well ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2007, 11:43:14 PM
Shaun's very kindly donated all the glass from his Pop for my own, as he's chopping his & will fit new glass afterwards. Thanks Shaun.  ;)
I picked up a set of interor door handles & window winders for 2 quid each at the Picket Piece classic vehicle show the other day, but still need the window winding mechanisms, door opening mechanisms & exterior handles.


Title: Re: Manky's Pop.
Post by: panthershaun on April 27, 2007, 08:54:05 PM
No problem mate ;) I'm almost certain that I'm going suicide doors with mine, so if you can wait awhile you may be able to have my door handles and associated gubbins.


Title: Re: Manky's Pop.
Post by: BikerGran on April 27, 2007, 09:18:24 PM
Suicide doors?  Is that a la 'Dukes of Hazzard' stylee?


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 27, 2007, 09:27:50 PM
No Bobbie, forward opening doors like Chris's Morris.

 


Title: Re: Manky's Pop.
Post by: panthershaun on May 04, 2007, 10:17:48 AM
I want those seats out of Chris morris >:(.
Manky can you do me a favour please mate ;) can you draw around the front screen and one of the door windows for me. I really need a template for when I get my glass cut and it would be easier if I had the original size glass to work from, but some idiot let it all go before I he thought about this :-[ :-[ :-[  also let me know when you decide to part with your Pop front axle, wouldn't mind a spare plus I have a cunning plan about building a REALLY cheap Roadster.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 13, 2007, 09:30:26 PM
Took my Pop along to the Basingstoke Transport Festival today, where it attracted more interest than the trikes!
Lots of little old men peering inside it.
Bob the merchandise guy printed off a couple of vinyl stickers for me, which we slapped on the doors. Looks like some old 50s banger racer now.  ;D


Title: Re: Manky's Pop.
Post by: BikerGran on May 14, 2007, 10:59:42 PM
Looks like some old 50s banger now.  ;D

Er, yeah..................


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 15, 2007, 11:37:11 AM
Trust me, it'll be pretty when it's done Bobbi! Honest.


Title: Re: Manky's Pop.
Post by: flap on May 15, 2007, 03:33:01 PM
It'll never be done so Lunatic's gonna keep chickens in it.


Title: Re: Manky's Pop.
Post by: tazet on May 16, 2007, 06:37:50 AM
So help him with the trike then he can move on to the pop  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 16, 2007, 01:49:28 PM
Yeah -what she said!  :P


Title: Re: Manky's Pop.
Post by: flap on May 17, 2007, 12:02:59 PM
How can anyone help him when he's never there doing it  ???


Title: Re: Manky's Pop.
Post by: BikerGran on May 17, 2007, 12:05:16 PM
Now now children!  No squabbling please!

Get on with it Manky, it's got to be finished AND inspected AND all the rest for the Cornwall Run!


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 17, 2007, 01:50:43 PM
I know, I know!
HELP!


Title: Re: Manky's Pop.
Post by: BikerGran on May 17, 2007, 04:26:20 PM
.


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 02, 2007, 05:18:04 AM
i could give you a hand with the pop mankey, dont know much about trikes but restoring and customising old cars is right up my street, ive probably got some parts that would come in handy too


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 02, 2007, 05:52:14 AM
Hmm, let me think -do I want some help with this one?

...YES, YES, YES, YES, YES!!!
                              -please.  ;D

My brother, Brock, is heavily involved in the drag racing & rodding scene & far more au fait with the design side of it all, so I'm hoping he'll have the time to get involved too. I just know what I like. Brock's a car guy with a liking for motorbikes. I'm a biker with a liking for cars. Never built a rod from the ground up but did plenty of work on my old Moggy Minors. It can't be that difficult -can it?
Biggest problem will be building with a budget of absolutely zero. Slightly less than zero actually. I want to keep things as 50s period correct as I can so will be re-using as much Pop or similar stuff as I can. Janie & Dave have very generously donated a 1700 Consul engine, (in need of a good check over & rebuild), box, column shift & rear axle. I've got a Sherpa van front beam axle with disc brakes which I was keen to use but Brock keeps telling me it'd be a lot of work, (& expense), to narrow it to fit, so maybe I need an alternative? Not sure the original Pop set up's man enough for the job as the Consul motor weighs twice what the Pop one did.
Not looking to build a glitzy show winner, just a good, solid daily driver.
This is basically the shape I'm after, though obviously without the huge motor & probably with banded versions of the original Pop wheels, (Lunatic knows of a place that does them under licence).


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 02, 2007, 08:20:26 AM
suspension wise it might pay to go independent such as a triumph herald or simillar, i dont think it would be too hard to fabricate the mounting points on the pop chassis


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 02, 2007, 09:04:20 AM
Yeah, Vitesse or Herald were always the first choice for Pops weren't they. I liked the Sherpa cos it's a beam axle like the original Pop one. It looks 50s. Also means I can use a steering box, rather than rack & pinnion, which'll give me more room & a tidier set up.
As I said, zero budget so can only go for Triumph gear if I can find it free or swap it for the Sherpa.
Anyone want a matched pair of front & back 200 series Sherpa van axles?


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 02, 2007, 09:28:02 AM
i might just be able to lay my hands on a chevette ifs


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 02, 2007, 08:27:58 PM
Hmm, interesting.  ;D
Would really like something that looks the part of a 50s rod, but buggers can't be cruisers, or whatever.
Can you grab a snapshot of the Shove-it bits? Is there a steering rack or box to go with that?


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 05, 2007, 04:03:04 PM
Full width Sherpa front beam on a '27 T, (the same body I've just given away in favour of my Pop). Also fitted with a Sherpa rear axle.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 05, 2007, 04:03:39 PM
Narrowed Sherpa beam.
I'm told this was built on an old Bedford ambulance chassis so possibly a Bedford beam, but very similar.


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 05, 2007, 10:13:11 PM
yup gotta agree it does look right


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 08, 2007, 08:03:06 AM
so then mr manky when does the pop build begin? ive got a couple of projects nearing completion so should have some time on my hands soon


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 08, 2007, 09:27:16 AM
Coo, you're keen!
It's sitting under a tarpaulin outside Lunatic's farmyard workshop in Monk Sherborne at the moment. Being a Postie, I've got every afternoon spare. Not sure how Loony stands with doing evening work. I suspect he can't cos he obviously needs to stay in the good books of the locals. Weekends are fine, but being show season I've got a few events I'd like to go to -either the Marlborough steam show or Mersea car show this Sunday, the Invicta Roadsters rod show next Sunday & the Nostalgia Nationals drag racing at Stratford on Avon the following week. You should come along to that one. Watch Brock break the Black Pig. Lots of gorgeous machinery.
We can work outside but will have to wait for a slot when Loony's between paintjobs to do anything indoors.
I'd really like to get Brock over to lend his expertise too. I freely admit I haven't got a clue where to start!
 


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 08, 2007, 10:59:13 AM
no worries just let me know when your ready, in the mean time feel free to nip in for a brew at the spanner fingers old car shop,


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 08, 2007, 11:22:38 AM
Thanks.  :D
Would be nice to add you to the list of shops in the Motors, 4 wheels bit -take some snaps, a quick description of the kind of stuff you do etc.
I'll see if I can pin Brock down to a day when he can come over. If not we can start without him, but would rather have his experience if possible. I guess we'd need to brace the body then remove it from the chassis & start looking at positioning the Consul engine & box & axles? The sills are off the body & the doors have dropped slightly. I've got the sills that came off but no point replacing them until we know if we're channelling the body or whatever.


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 08, 2007, 11:54:42 AM
yes it would need bracing for sure, some of that tube you make the trikes with would be ideal across the door shuts and between the B pillars etc.
i have a few projects on the go up here that may be of interest to you and the other monkeys including a classic jag with modern mercedes diesel engine and a honda cafe racer plus various other classics under going different levels of work, so bring ya cam and note pad.
p.s dont forget the cakes


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 08, 2007, 11:56:59 AM
Nothing to stop you posting pics on the forum you know -but yup, I'll try & call in one day next week.  ;D


Title: Re: Manky's Pop.
Post by: lunatic on June 08, 2007, 07:18:38 PM
Evenings over at the shop are fine until about half ten. Be good to work a few evenings, stop me sitting in front of the tv every night!


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 08, 2007, 09:24:37 PM
Would stop me sitting here writing drivel every evening too. :P


Title: Re: Manky's Pop.
Post by: brock on June 08, 2007, 09:32:27 PM
   well have a look at this instead then, this is a link to the "Volkswagen " engines we were speaking about earlier

http://www.staggsracing.com/2StaggsEngines/StaggsEngines.htm


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 08, 2007, 09:52:41 PM
My older & more talented brother Brock arrived at my garage this afternoon. Very nice to see you Steve. After mooching around, poking the trike with sticks for a while, we wandered over to Lunatic's place to mooch around the Pop for a while.
Loony's dad, Psycho T, was there, along with Janie & Dave. Still seems a shame to cut the body up but I definitely want a pick up so it's gotta be done. As Loony said, there's hundreds of average saloons about but very few good pickups.
Been looking for a means of creating the compound curves of a new cab back. First suggestion was to re-use the curves at the top of the bootlid, but a check with Loony's profile guage thingy ruled that out. Then Mr Brock had a brainwave. Lunatic's got 3 or 4 VW camper vans in his yard. The corners of the rear valance are available as a repair panel for about 10 quid each. Loony just happened to have an old one in the workshop. Turn it on it's side, offer it up to the roofline -perfect. Hopefully, with a pair of those, the rest can be formed from flat sheet with the rear window from the Pop being recycled as well.
  


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 08, 2007, 09:53:25 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 08, 2007, 09:54:52 PM
Or maybe I could pinch Lunatic Senior's FireBird wheels & build a gasser.


Title: Re: Manky's Pop.
Post by: panthershaun on June 09, 2007, 05:32:34 PM
Nice one Andy, check this out http://z13.invisionfree.com/VolksRods_UK/index.php?showtopic=590 and follow the build through, explains how they built the cab back.


Title: Re: Manky's Pop.
Post by: BikerGran on June 09, 2007, 06:42:42 PM
I've seen some opf that stuff when I take the car to my mechanic - he's got a unit across the way, you can see it in one of the phots!  Totally irrelevant but there you are....


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 10, 2007, 08:56:26 AM
cant you move the C pillars forward and maybe have a tiny side window like the aussie utes?


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 10, 2007, 09:45:03 AM
Could do -that's what Desperate Dan did with his Morris 8 pick up, (see the Motors, 4 wheels section of the main site). I'm not keen on the sloping cab backs of the Ozzie utes though. Here's a pro street one from Billing last week. I'd rather have a flat backed cab. That creates problems trying to get the roofline to flow smoothly from horizontal to vertical though. Using the top edge of the boot seemed a good idea but would give a sloping cab back when the curves were matched up so not what I'm after. Shaun's using the steel back panel from a Moggy Minor pick up, which would be ideal, but they're pretty scarce & priced accordingly, so beyond my non-existant budget. The VW panels look to be near perfect. My only worry is they're quite flimsy so welding old heavy guage steel to new paper thin stuff will be fun.


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 10, 2007, 10:46:03 AM
i have a few old panels here i will have a nose and see whats what, just might be something usefull


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 10, 2007, 04:55:24 PM
Thank you. Feel free to nip out to Lunatic's place & have a measure up of the Pop!


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 10, 2007, 05:24:28 PM
couldnt find any repair sections that would be suitable but may have found some seating, i know seats are a long way off but its worth getting while you can, i found an old rear seat that would make a great bench, and a few sets of fronts that might be useable, i will take my camera in tomorrow and grab some snaps


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 10, 2007, 05:57:56 PM
My Moggy Minor pickup had the back seat from an Austin Allegro as a bench seat.
I actually like the ripped up brown leather original Pop ones. Happy to run it with those -unless you have a similar brown leather rear? The car's rear, not yours.
The dashboard is bakalite & the steering wheel's brown so got to be brown seats.


Title: Re: Manky's Pop.
Post by: captainspannerfingers on June 10, 2007, 08:49:18 PM
oooooeeeerrrrr i do worry :o


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 11, 2007, 09:00:09 AM
I was down Wiltshire way for the steam & vintage fair yesterday, just outside Marlborough. Many photos here:
http://www.mankymonkeymotors.co.uk/Photos/wiltssteam10.6.07/

-"whoar, tha's a noice trac'or. Tis a thing o' beauty is that".
Had a great afternoon out all by myself, (Tazzie was busy horse eventing in Hampshire).
Anyway, I bought a pair of brand new tractor headlights from one of the suppliers stalls.
5" diameter, ball jointed, black painted, high & low beam, plus sidelight, (including bulbs. 10 quid each. Bargain.  ;D
Not owning a tractor, I'll pop 'em on my Pop.


Title: Re: Manky's Pop.
Post by: brock on June 11, 2007, 05:50:41 PM
   having seen the Pop , I'd keep an eye open for a tractor if I were you

 
 Big and little rubber, open sided engine bay, torque monster motors, big long gear sticks , vauge steering, it's all done for you


Title: Re: Manky's Pop.
Post by: lunatic on June 11, 2007, 06:20:12 PM
 Big and little rubber, open sided engine bay, torque monster motors, big long gear sticks , vauge steering, it's all done for you

I have an overwhelming urge for a tractor. Now I know why!  :D
I just want one to drive around the country lanes on! 8)


Title: Re: Manky's Pop.
Post by: TwistedPatience on June 11, 2007, 07:19:54 PM
Arr an you can see over the hedges in one of them too!

An keep yer scrumpy un'er the seat 'anall.


Title: Re: Manky's Pop.
Post by: panthershaun on June 11, 2007, 09:46:18 PM
I have driven an old Fergie fitted with a rover V8 ;D ;D ;D ::) :o :-\ ::) bloody mental it was ;D ;D ;D ;D


Title: Re: Manky's Pop.
Post by: tazet on June 12, 2007, 07:56:15 AM
Oh I'm so lucky with my job as I get to play in tractors every day  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 12, 2007, 08:33:03 AM
What's wrong with my Pop? :(


Title: Re: Manky's Pop.
Post by: tazet on June 12, 2007, 04:10:35 PM
Nothing is wrong with it hun. I can't wait till its on the road, it will be great fun  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on June 13, 2007, 10:12:15 AM
nothing wrong with it mate...............................yet ;D ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 13, 2007, 10:54:17 PM
You lot really know how to dampen a guy's enthusiasm don't you.  :(
It's still very tempting to just bung glass & an engine in it & run it exactly as it is. Just 2 tatty old leather seats & a steering wheel & nothing else. A pickup is what I really want though, but it seems like more & more work the more I discuss it with people. Brock keeps telling me I need to think about over steer & under steer & camber & trail & Gawd knows what else, & that I should design & build a whole new chassis.
I just want to stuff the Consul engine in & drive it.
Having purloined a matching Consul rear axle from Janie & Dave, Mr Brock now reckons the Sherpa van one I've got in my lockup would be better geared for the 15 or 16" wheels I plan to use, (Consuls use 13"s). It'd also mean I'd have the same bolt pattern on all 4 wheels as I still intend to use the Sherpa's disc braked front beam.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 18, 2007, 08:32:03 PM
http://www.northernhotrodclub.com/page6.htm#

Have a look at this Pop. This is exactly what I'd like to do with mine, except with a column shift Consul motor, plated & Z'ed original chassis & beam front end.


Title: Re: Manky's Pop.
Post by: panthershaun on June 20, 2007, 07:02:52 PM
that is bloody near perfect Manky, just throw away those shiney hoops for a set of steelies


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 20, 2007, 10:56:23 PM
How did you extract that picture?! I tried but it wouldn't let me.  :(
Yup, exactly what I want.


Title: Re: Manky's Pop.
Post by: panthershaun on June 21, 2007, 09:56:54 PM
just gotta know how ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 22, 2007, 11:25:54 AM
I know nuffink  :( -as I regularly prove here.


Title: Re: Manky's Pop.
Post by: panthershaun on June 22, 2007, 07:04:27 PM
Click on the thumb-nail and as soon as the picture has opened right click and save image as, but you have to be quick. :o then close that window and click on next thumb-nail etc etc


Title: Re: Manky's Pop.
Post by: lunatic on June 22, 2007, 07:20:47 PM
Nicest pop pick up Ive seen I reckon. 8)
So far anyway! ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 22, 2007, 08:03:37 PM
Yup, until Shaun's & mine are done anyway. ;D
I'll try that Shaun so I can keep the pics for future reference.


Title: Re: Manky's Pop.
Post by: panthershaun on June 22, 2007, 08:26:55 PM
Mine is going to be the best :P :P :P :P so there ;D ;D ;D ;D ;D if you can't get the pictures Manky, let me know as I have all of them ;D ;D.

Did you get the sticker pictures ??? and will the mobile advert (Bobcat) be featured ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 22, 2007, 09:09:56 PM
No Shaun, no sticker pics via email yet.  :(
Captain Spanner Fingers was going to take a shot of a sticker in the window of his Pop too, but hasn't yet. No reason why we can't use Bobcat -as long as you don't want commision! ;) I took a few snaps of it at the Hopfarm but feel free to take a better one.
Yep, if you've got the Pop pickup pics, could you email them to me please.


Title: Re: Manky's Pop.
Post by: panthershaun on June 22, 2007, 09:11:48 PM
I will email them tomorrow Andy, off to bed now as I have an early start tomorrow and have some strike pay loss to make up >:( >:( >:( >:( :-X


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 22, 2007, 09:29:50 PM
Same here. My day off tomorrow but doing my own delivery on overtime. Thought I'd be a few quid better off next week but now the strike will wipe that out.
And mine will be the prettiest Pop!  :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 04, 2007, 04:37:11 PM
Got your sticker photos Shaun. Thanks. Will get the Merchandise Page updated accordingly.

Tazzie & I borowed a van from Captain SpannerFingers yesterday & drove halfway across the World -well, deep into darkest Wales anyway. "Zed" from the BritChopper forum was selling some Moggy Minor parts & thanks to a shout from PantherShaun I was able to buy a steel Moggy pick up cab-back & roof section for 40 quid. Shaun wants the roof to replace the vinyl panel in his own Pop project & I wanted the cab back, so we went halves.
Zed & his good lady Jill turned out to be very nice people. I'm hoping they'll send in some pics of their Yam Wild Star chop & ongoing Panther project with Norton belt drive conversion. We left Basingstoke at around 7 in the morning, collected the parts from Wales, stopped off for a little sight-seeing & a bag of chips on the way back & finally got home at 10 last night. So we just dumped the cab panel at Lunatic's yard, where my Pop's in temporary storage. I nipped back after work today & took a quick piccie for you.
We measured it up & although it looks wider, the Moggy part's actually 2 inches narrower than the relevant bit of the Pop body. So hopefully we can tweak it to suit. Some rust damage, but all the important bits are intact & it's not bad for 20 quid. I've also got the original Moggy glass, (but not the rubber), so will probably keep the full size rear window when we chop the roof.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 04, 2007, 04:45:40 PM
Here's the same panel fitted to a Pop, but with a modified rear window.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 15, 2007, 10:34:05 AM
cracking thread/Pop project :) luv the concept that yer heading for keep up the good work :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2007, 11:25:35 AM
Thanks  :)
Shaun & I will both be building Pop pickups this Winter, both fenderless, 50s basic hotrod style, re-using as many orignal parts as we can & definitely both on shoestring budgets. So it'll be interesting to see what rolls out of our respective garages in the Spring!
I plan to keep the original tatty brown leather front seats from mine, together with a Bakalite dash from a 40s Ford Prefect & early LandRover or Morris Minor "banjo" steering wheel, both picked up from the NSRA swapmeet in Purfleet earlier this year. I want to spray the bodywork in the pale green used on original Pops.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2007, 11:27:53 AM
Shaun intends to carry his old Panther motorcycle in the pickup bed of his rod, so obviously it needs to be long enough to accomodate it. Something like this, without the mudguards & with a 3 inch roofchop.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2007, 11:32:56 AM
I wanted a 4 inch chop, but after much discussion, agree with him that 3's more practical for everyday driving -enough to show it's chopped without being too claustrophobic or looking out of proportion with the body. It'd be nice to be able to see the sky occasionally when driving! -& traffic lights etc.
I'd like to "Z" the original frame either end of the cab, to drop the cab lower without the need to channel it over the chassis. That'd raise the engine within the body, making it look bigger, as well as raising the pickup bed, making the roofchop look lower. I'd prefer a slightly shorter, sportier looking bed.
I really like the lines of this, but with a slightly more sensible motor!


Title: Re: Manky's Pop.
Post by: TwistedPatience on September 15, 2007, 12:13:43 PM
Looks like a perfectly sensible motor to me! but then I'm not the most sensible bloke around eh!


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2007, 12:23:47 PM
 ;D With that roofchop & inlet stacks he must have about 4 square inches of windscreen he can see out of!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 15, 2007, 08:03:50 PM
sheesh those plans sound like the Pops of you twos is gonna be well smart,like the idea of the Z setup i like the dropped cab look nice too see some peeps chasing yer dreams :) u still using the moggy panel,the pickup one? cant wait to see wot the two of u do luv the idea of the pickup Pop versions reminds me of Krazy customs car/bike combo that happens to be green too, well i'll just sit back in admiration :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2007, 08:27:33 PM
Yup, we're both using steel Moggy cab backs.
Watch this space!


Title: Re: Manky's Pop.
Post by: panthershaun on September 28, 2007, 07:56:03 AM
keep watching, it will happen one day ;D ;D ;D if this rain ever stops >:( >:( >:(


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 28, 2007, 12:25:09 PM
Can't wait to make a start on them.
Shaun reckons he's chopping the roof & sorting all the other body mods first, then strengthening the chassis if it needs it afterwards.
I plan to add some temporary bracing to the body then lift it off in one piece. Rework the chassis -cutting & dropping the centre section then boxing it for strength, adding Sherpa axles & a Ford Consul motor. Then I'll drop the body back on & remodel it to fit.
Will be interesting to see which works out best.  :)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 28, 2007, 12:52:34 PM
will that be in the new workshop Manky? or u starting it at loonies?


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 28, 2007, 12:58:32 PM
New workshop?!
Tazzie's got a wooden shed at the bottom of her garden, where we'll put together her trike over the Winter/Spring. I've got a rented council garage in Basingstoke where I'm piecing together my own trike. The Pop's too big to go in either so will, (hopefully), be done at Lunatic's workshop, (a unit on a farm). As he's a paint sprayer, all the messy stuff will have to be done outside, so the weather will play a big part in how long it takes.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 28, 2007, 01:05:53 PM
Oh right when i was reading the ideas surrounding tazets place i think you mentioned if the sale works out there may be room to expand that current shed? i maybe wrong or just thinking to far ahead,typical dreamer me :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 28, 2007, 01:13:57 PM
Yup, some sort of expansion but not sure what yet. Part of the reason for clearing the bottom of the garden this weekend, so we can see just how much room we've got. The cottage isn't ours, it goes with Taz's job, so don't want to invest too much money in it. Also depends on her boss & her neighbours as to how much we can develop it. This is the Surrey countryside we're talking about! -a fully equipped machine shop in the back garden might not go down too well!
The existing shed's the size of a council garage. We can probably put up another the same size & maybe even link them together providing it doesn't contravene planning regs. Can't really build the Pop there but once it's done I'd like some sort of carport to keep the worst of the weather off it.
We'll see.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 28, 2007, 01:27:55 PM
sounds good anyway :) with enough scope to continue Manky frames etc and space to park the Pop at least :) i ahve one open air carport and two corriders lol so could be worse :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 28, 2007, 01:59:21 PM
Build your trike in the living room!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 28, 2007, 02:01:56 PM
your not far wrong there


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 28, 2007, 02:06:58 PM
Never gone quite that far, but I have sprayed a petrol tank in the spare bedroom -then had to completely redecorate afterwards.  :P


Title: Re: Manky's Pop.
Post by: tazet on October 21, 2007, 05:40:11 PM
What a great day to be playing with the pop at Lunatics workshop. We've taken over 400 pictures so will take a while to sort through them.

Manky will be on line soon to fill you all in properly but just in case he forgets to mention. I did the first cut and did the whole roof length all by myself and the line was prety straight if I do say so myself  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on October 21, 2007, 08:06:10 PM
 ;D ;D ;D ;D :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 09:31:05 PM
Right, here goes then!
I bought my Pop, (which actually isn't a Ford Popular at all, but a 1953 Ford Anglia), from Neil on Ebay for 450 on the 25th February this year. Since then it's spent it's life being shunted from place to place until today, almost 8 months to the day since we collected it, we finally took the tarpaulin off, stood back & said
-"Hmmm, what're we gonna do with this then?"
I'd always wanted a pick up, but this ol' saloon just seemed too nice to cut up. After lots of hesitating & changes of plans & a Summer of checking out all the other Pops at various rod meets & shows though, I had to agree with PantherShaun that there's bloomin' 'undreds of Pop saloons out there -some very nice, some truly horrible, but very few pickups, particularly reasonably tidy ones. So the decision was made.
Taz & I travelled over to Wales & picked up, ( ;D), a steel Morris Minor pick up cab back, which Shaun assured me would be a pretty close fit on the Pop body, for 20 quid. At the Spring NSRA swapmeet we bought a Ford Prefect bakalite dash, a "banjo" steering wheel, (either original Pop, early Landrover or early Moggy Minor), plus a set of 4 black taxi cab wheels, which turned out to be a pair of 16 inch taxi wheels & a pair of 15 inch unknowns, maybe Austin Devon or similar.
I've also got a pair of Sherpa van axles, (same bolt pattern as the wheels, with a vintage looking beam front fitted with disc brakes).
The final part in my inventory was a 1700 Ford Consul engine with 3 speed column shift gearbox, but that's now up for discussion.
The MMMotors crack engineering team assembled at Lunatic's rural workshop this morning to assess the build. Loony & PD, Janie & Dave, plus Tazet & I. Dave immediately threw the plans into disarray by telling me he's been offered not one but two engines -a V8 Rover with auto box & Rangerover headers & a Granada V6, 150 quid each. He wants one & I can have the other. Bugger. So what do I go for?
So- first job. Unbolt the body & lift it off the chassis to get some idea of what we're facing.     


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 09:34:04 PM
We took so many photos today I've actually made up a gallery for them & added some explanatory words in the Motors, 4 Wheels section of the main site here:

Pics of the Pop (http://mankymonkeymotors.co.uk/Hotrodpageimages/pop21.10.07/build.html)

So won't bother posting too many here. Read this, then go have a look.


Title: Re: Manky's Pop.
Post by: panthershaun on October 21, 2007, 09:37:01 PM
V8 or V6 gotta be better than the consul lump ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 09:41:02 PM
Yeah, but which Shauny?

The previous owner had already taken the body off & temporarily tacked it back on with a few L shaped brackets & nuts & bolts, so no great dramas in removing it.
Before we did though, we took the precaution of hoiking the doors back into line with the bodywork & tack-welding them shut. Then we used some lightweight steel tubing, (an old set of garden gazebo poles!), to brace the interior -2 in a cross shape from corner to corner, plus a horizontal one at the back & another at the front.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 09:43:48 PM
Up, up & away!  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 09:47:58 PM
The 50 year old body's considerably firmer than mine!
The chassis ain't in bad nick either, but looks so flimsy. It's made from U shaped channel, so we'll plate the open 4th side of the rails to make a much stiffer square box section.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 09:58:25 PM
I plan to drop the centre section of the chassis by 6 inches, by "Z ing" it at both ends. That'll drop the cab unit down, giving it 5 inches of ground clearance -essential in Basingstoke, land of the speed hump & pothole, with the two ends staying at original ride height. Dropping the chassis with the body on it, rather than channelling the bod over the rails, means it'll retain full headroom inside. Next job will be to chop 4 inches out of the roof height.
The Sherpa axles will add 3 inches to the width either side, but as we're not bothering with the original front wings & there'll be a new pick up bed on the back, it won't matter.
After unbolting all the unwanted original Pop parts from the chassis, a test drive was obviously needed.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:00:18 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:02:53 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:06:25 PM
Yup, that's fine, but the brakes might need a little work.

So that was us done for the day really

...but isn't it tempting to start cutting that body up...


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:08:22 PM
Ha harr!! Cut it! Cut it!!

...oh, alright then.
First cut went to Mrs Manky.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:12:06 PM
Didn't take long to reduce it to this.

Oooh, bugger. No going back now. :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:13:07 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:14:17 PM
Anyone fancy building a Ford Pop based beach bastard trike?


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:16:45 PM
Next, try the Moggy cab back in place. It's about 2 inches narrower than the Pop but nothing that can't be fixed. Looks promising, (we've deliberately cut the Pop an inch too long so we've got room to trim it exactly later).

That chasis still looks kinda flimsy to me.


Title: Re: Manky's Pop.
Post by: panthershaun on October 21, 2007, 10:20:33 PM
B*stards  >:( >:( >:( >:( >:( steaming ahead I see ::) ::) why not weld the Pop back end to a Beetle front 8) 8) 8) :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:30:00 PM
Don't tempt them!!

O.K, enough buggering about for today.
A final mock-up of the job so far.



Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:31:48 PM
No sills fitted here. They finish flush with the underside of the chassis. Body's just propped in place.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:33:09 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:33:59 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:35:00 PM
The cab will sit 6 inches lower, with another 4 inches cut out of the roofline. That'll hopefully bring the side windows down to exactly the same height as the standard Moggy Minor rear window. By Z ing the chassis, rather than channelling the body, there'll still be headroom inside. The seats can be moved back 6 or 7 inches to improve legroom. The front axle will be mounted 8 inches further forward to give more engine room & bring the front edge of the tyres in line with the radiator grille. The rear axle will also be shunted back to visually balance things out a little more. The pick up bed will be short & sporty, (to be honest, it's only there for show -I won't be hauling much in it). Might mount the original oval Pop fuel tank in the bed behind the cab. The top of the pick up bed will be level with the bonnet. Tall, skinny 50s style crossply truck tyres with black cycle guards on them.
Any observations? Constructive criticism gratefully received guys.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:35:41 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2007, 10:36:19 PM
.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 22, 2007, 09:49:18 AM
thats looks fcking brill already :) yer lucky having friends around you to make light work of the project :)


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 22, 2007, 09:53:57 AM
nice.


Title: Re: Manky's Pop.
Post by: TwistedPatience on October 22, 2007, 11:44:07 AM
I want one !


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 22, 2007, 02:00:02 PM
You've got friends too VB, we're just a bit further away that's all.  ;)
I used to run a Moggy Minor pick up that looked just like this a few years ago. Just a cab unit on rails. Looked like something out of The Waltons, with every panel a different colour, but so much fun to drive.  :)
Apart from petrol money, this has cost me around 500 quid so far. Dave-Postie reckons his mate's got 2 running engines, a V8 & a V6, both autos & both running, for 150 quid a piece. I really don't want to go the well trodden route of Rover V8, Viva front suspension & Jaguar IRS rear, so the 6 is tempting, plus it'd be slightly more sensible & economical -but then, when did sensible ever figure in the equation?! Plus the V8's so common in Pops that you can buy mounting kits to bolt it straight in, uprated suspension etc. My only worry is whether the boxed chassis is up to the job. Brock keeps telling me to scrap it & start with a fresh, purpose made one & Dave-Postie knows of a local frame builder, (I'd love to persuade Brock to do it as he's already building his new drag car chassis, but know he's way too busy). The main reason for abandoning my model T rod project was cos I couldn't see any way of legally registering it for the road -the SVA regs are really tight for one off cars. Buying the Pop meant I've got something that's already registered. Not sure plonking the old body on top of what would basically be a brand new car would sneak through the ever tightening MOT. So I'd like to keep the original frame if I can.
You guys are welcome to come over to the yard & roll up & down it on the Pop go-cart if you want!  ;D   


Title: Re: Manky's Pop.
Post by: Chevy Rick on October 22, 2007, 02:24:00 PM
Tis looking good Andy you had some fine helpers :D congrats to you all ;) , i could hear you all banging away while talking to Janie on the phone ;D


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 22, 2007, 02:51:23 PM
engine wise id go for  a straight 6 jag engine beauty of an engine and not many used in any thing as far as i now :) in yers gone by me and few m8s have used these to great effect and not sticking with the crowd ie v8s v6s :) i didnt mean the friends thing in a sad way, i was hoping to say it more like its nice to see friends all mucking in


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 22, 2007, 03:58:33 PM
We've got some very mucky friends!
There's an AJ6 4 litre Jag engine & box sat outside my brother Brock's workshop. It's been there for about 18 months now, gradually disappearing into the weeds. I was going to use it in the 27 T rod I was going to build. A physically huge motor. Very heavy. If I put that in the Pop it'd flip it up on it's nose! Anybody want it?


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2007, 05:50:46 PM
Doc, I've only just realised you've Photoshopped this pic!
I only spotted it cos the fence panels don't line up properly behind the cab! I've got P/Shop but no idea how to use it.
Can you drop the cab unit 6 inches between the wheels? (half the height it is now).
And Happy Birthday by the way! ;D


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 23, 2007, 07:06:51 PM
thanks,no bother ,how about ?


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 23, 2007, 07:08:51 PM
not photoshop mate,its called MGI photosuite,dead simple to use.and its free.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2007, 08:56:21 PM
I'll have a look at that matey.
The second shot, with the bottom of the body shaved, looks pretty cool but I'll stick with the dropped body & roofchop I think!
So- can you add a pickup bed? The length of the existing chassis rails & running level with the bottom of the windows/top of the bonnet. Oh, & it'll be pale green with maybe cream wheels. ;D


Title: Re: Manky's Pop.
Post by: tazet on October 24, 2007, 05:59:53 AM
With the Logo left on the side too  ;D


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 09:56:19 AM
crap attempt


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2007, 11:37:06 AM
 ;D Looks fine to me! I'm gonna build it just like that now!


Title: Re: Manky's Pop.
Post by: tazet on October 24, 2007, 11:59:20 AM
Hey looking good  ;D


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 01:15:36 PM
both wheels same colour  ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2007, 02:25:17 PM
Oi! You've hijacked my truck! MMMotors logo in black outline please!
The bed looks about right there, which suprises me -I thought it'd have to be longer to look in proportion to the rest of the car. The benefits of photo manipulation eh.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 02:31:29 PM
oops ,some people will do anything for free publicity eh? sorry MM, ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2007, 02:34:17 PM
Bloomin' cheek!  ;D


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 02:37:05 PM
fixed ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2007, 02:40:21 PM
 ;D
That's better!
Got to be a plain black outline version of the logo though I think -the red will really clash with the green.
Bet you can't do that!


Title: Re: Manky's Pop.
Post by: lunatic on October 24, 2007, 02:40:54 PM
'Ere Doc, do you think you can shift the front wheels until the tyre is level with the nose of it?


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 02:47:53 PM
?


Title: Re: Manky's Pop.
Post by: lunatic on October 24, 2007, 03:06:06 PM
Thanks doc. We are planning to run the new axle further forward when the chassis gets done, hope that answers the ?. ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2007, 03:39:09 PM
The opposite of that Doc -just an outline drawing as on our T shirts.
Wonder how difficult it is to get through the SVA? Or do I just change the vehicle description on the logbook from saloon to pickup & see what happens?


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 03:55:28 PM
?? ;)


Title: Re: Manky's Pop.
Post by: TwistedPatience on October 24, 2007, 03:57:23 PM
Matt Black!


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2007, 04:45:21 PM
Nah, black's too common. That's it Doc. I'm planning on this Ford green.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 05:56:42 PM
close to it as i can get.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 06:00:39 PM
took the liberty of making your pop a bit more radical
drop body
kick out front
kick out back
lose moggy back panel
use pop back end
ford green
logo
cream wheels


Title: Re: Manky's Pop.
Post by: tazet on October 24, 2007, 06:09:40 PM
Almost a crew cab. I like it  ;D More room for cake  ;D


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 24, 2007, 07:17:38 PM
exactly  ;D and not instantly recognizable as a pop,which is the point ,isnt it ?


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 24, 2007, 07:35:10 PM
im starting to feel sick :D


Title: Re: Manky's Pop.
Post by: Plainy Janie on October 24, 2007, 07:51:55 PM
Someone mention cake?   MMMMmmmmmmm


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2007, 09:16:17 PM
 ;D
We talked about using the Pop rear section for the cab when I first bought it, but not personally my taste. That's how the Australian export model, (the Ute), was done. Pete Moore's is on the cover of the new issue of Custom Car, (Nov. 07). And it's green! Desperate's Morris 8 in the Motors, 4 Wheels bit's done by shunting the rear of the body forward too.

http://mankymonkeymotors.co.uk/Hotrodpageimages/morris/8.html


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 25, 2007, 09:03:27 AM
i think that DD's car is well cool(cos its not instantly recognizable as what it once was)but still looks like a production model,sort of.


Title: Re: Manky's Pop.
Post by: panthershaun on October 25, 2007, 07:49:17 PM
V8 good light(ish) sound engines, and I think that they are lighter than the V6.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on October 26, 2007, 10:11:18 AM
how could you not want this ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 26, 2007, 07:39:34 PM
 ;D
Seen it at a few shows this year & it's absolutely flawless, beautifully put together, but just not my cup of Earl Grey. Not keen on the domed cab shape. Also unsure about the way the pick up body flows out of the cab bodywork. Much narrower doors than a normal Pop too. I prefer a good old fashioned traditional seperate pick up bed & straight backed cab personally.
'Tis nice though.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2007, 11:21:24 PM
O.K, day 2 of the Pop build saw a different line up of Monkies back in the workshop. Tazet's away for the weekend & Janie & Dave were busy, so then there were 3 -Lunatic, PD & my good self. Flap arrived while we were still in the "Hmmm" stage -standing back, taking a good look at the job in hand & going "Hmmmm". He'd heard we had donuts. He stayed just long enough to plunder our commestible stash then buggered off to play with his Landrover. Nice to see you again anyway mate. Later in the day Mr & Mrs Lunatic Senior also came along to see what we were up to.
So- where do we start then?
Lots more bracing I think. We'd put a basic framework of lightweight tubes in before taking the body off the chassis & cutting the rear section off, but removing the roof would take with it any last semblance of rigidity. So a network of cross braces had to go in to minimise the risk of the whole thing collapsing like a big wobbly car shaped jelly thing.  


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2007, 11:26:06 PM
The doors, which we'd previously tack-welded shut, also had to come off at this point, which meant even more tubing. This thing's better braced than the Forth Bridge. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2007, 11:35:07 PM
The original sills were supplied loose with the car when I bought it & closer inspection revealed why. The front ends had been repaired once before & rotted through again, while the bottoms of the A pillars where the sills attach were made up of 10% wafer thin steel & 90% filler.
I've checked the "Pop Brown's" catalogue & new sills go from 45 quid + VAT each to 95 + VAT, depending on the quality. They do A post repair panels for 85 quid + VAT each.
So we'll repair what we've got with a sheet of new body panel steel from Loony's local supplier for 7 quid delivered.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2007, 11:43:24 PM
I plan to run the Pop with an open sided engine bay -much discussion on the pros & cons of various engines has led me back to the tried & trusted, though boringly predictable, Rover V8 choice. So the inner wings have been junked with just a small spar from their top edge remaining to act as a brace for the bonnet flaps. We've also trimmed back the A post leading edges to suit.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2007, 11:48:04 PM
Luckily, someone's already done a pretty good job of filling the roof panel. After the War steel was in short supply so to save money Ford used a vinyl insert stretched over wooden spars in several of it's 40s & 50s models. A rodders' favourite trick is to use the large flat expanse of steel sheet from a modern car bonnet or van roof. You can see the original opening inside the car here.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2007, 11:50:09 PM
The windscreen pillars had wooden inserts to tack the headlining to.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:05:00 AM
I'd planned to go for a 4 inch chop to bring the side windows down to the same height as the rear Moggy Minor one, but a phone call from PantherShaun, as we were literally poised to make the first cut, persuaded me to go for 3 instead. He & his helper, Grizz, were also chopping their Pop today & had stolen an early start on us. He advised me that 3 inches would bring the windscreen down to just over 7 inches tall, (he thinks that's the legal minimum), & that any lower would render the car undrivable. So 3 it was. Thanks Shaun.
Nothing very high tech about the actual cut. We measured halfway up the rear pillars from the swageline on the body, then 1 1/2 inches either side of that centreline to give us 3 inches. Fortunately the same moulded line ran through to the front pillars so they were marked, measured & a horizontal line drawn around each pillar on a band of masking tape.
Let the cutting begin! 


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:07:47 AM
At this point we realised that if our braces didn't hold the thing as solid as a rock, the 4 corners would be left swinging about in space once the lid was peeled off.
Too late to go back now!


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:09:10 AM
.....Success!!
We now had a cabriolet cab. Or a pile of interestingly shaped scrap metal.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:12:26 AM
The required 3 inches were sliced off the pillars.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:18:23 AM
And the roof was plonked back on.
We were stunned to discover it actually fitted pretty damn well. The front windscreen pillars line up beautifully, with all the moulding lines flowing almost perfectly. Nothing that can't be finished to perfection with a little time & patience.
Because the roof section's moved forward to line up the front pillars, the rears are about an inch too far forward. Sideways though, they're spot on. So we'll slice them off under the gutter line & slide them back to reattach in their original positions. With luck we won't even have to add any filler strips of steel into the rear of the roof panel as the cut line lines up with the bottom half of the pillars nicely.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:24:09 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:26:32 AM
Lunatic did a quick check of the symmetry of our cuts by making a cardboard template of one side of the windscreen, then flipping it over to check the fit on the other side. Spot on. Damn we're good!  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:29:27 AM
The front pillars are now virtually finish-welded with just a little fettling & smoothing off to do, while the rears are tacked in place for the time being to keep everything nicely aligned. Next time we'll slide the top of the rear pillars back & fully weld them too, before moving on to the doors.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:32:48 AM
Amazing what a difference 3 inches can make!  Much meaner looking now. Shaun was right, 4 would've been too much.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 12:40:40 AM
A bit more "Hmmmm" time -I'm having second thoughts about the green paint now! The black looks much more vintage &, much as I hate the very over-done satin black paint with red wheels combo, I like our red & cream logo against the black. Maybe get the body as straight as we can & go for high finish glossy black with the logo on each door & cream wheels to pick up on the cream in the logo? Perhaps with a simple red coachline along the swageline in the door panels, extending along the top of the pick up bed & the bonnet to tie it all in together?
Ahh well, time to roll it back inside for another night. All in all, a good day's work I think. Many thanks to Lunatic for his welding, (I'm not used to working thin sheet steel, as I mainly weld heavy gauge tube for trike frames). Also to PD for his able assistance. Thanks guys.  ;)


Title: Re: Manky's Pop.
Post by: brock on November 05, 2007, 01:35:49 AM
   very , very , impressed.

   thought about laying the B posts forward, quadrant cut lower front at the waist line and below the gutter at the back, sort of makes the lines flow a little smoother ( that'll be an opinion in case you didn't spot it  ;) )


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 05, 2007, 07:50:55 AM
cracking work Gents..but then i said that already in shauns thread!!as mankies pop is over spilling in there too :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 02:00:07 PM
"very , very , impressed".

-Really? That really means a lot. Thank you.  ;D
Sloping the rear pillars above the waistline would take us back to the Aussie Ute shape again wouldn't it. I'm just not keen on that dome-headed look personally. I prefer the more traditional straight backed cab style.
Even just leaning into the cab over the cat's cradle of bracing poles, I can feel it's gonna be quite claustrophobic to drive. Spread your fingers as wide as you can then hold them up in front of your face -that's the height of the screen I've got to peer through. Stick a large diameter steering wheel in there, windscreen wipers, rearview mirror, tax disc etc & suddenly there's not an awful lot of glass left.
Shaun & I have both gone for 3 inch chops but it turns out my 3 inches is bigger than his! Team Panther measured theirs on the sloping front screen pillars while Team Manky went for the rear upright ones. So ours is a true 3 inches lower while theirs is something like 2 3/4. As Shaun said, it'll be interesting to compare them side by side.



Title: Re: Manky's Pop.
Post by: mouse on November 05, 2007, 03:25:24 PM
thats looking very cool andy spot on m8


Title: Re: Manky's Pop.
Post by: Firery Fred on November 05, 2007, 08:30:28 PM
Hi Andy,not really into 4 wheelers but must admit this looks great.There's a Chevy that looks like Ricks,well it does to me the amateur,riding around up here at the moment,sort of cream colour,but I can't catch the guy parked anywhere to get photo's or a chat,catch you later,Fred


Title: Re: Manky's Pop.
Post by: panthershaun on November 05, 2007, 09:08:25 PM
Nice one Mr Manky. you guys went about the chop a completely different way to Grizz and me. Actually I was Grizz's helper :-[ as he is the expert and I am the novice but next time >:( >:( >:( got some killer idea's in my head :o ::) :-\


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2007, 10:15:18 PM
Nab him when you get the chance Fred & send us in a write up & pics please!

Shauny, we certainly didn't have an expert on our team -none of us had tried anything like this before, though Lunatic, Postie_Dave & I are all hotrod fans & have read numerous roof chopping articles in magazines over the years. It's a different matter when you're stood looking at your car with a grinder in your hand though. Maybe it was beginner's luck, or just ignorance of the potential pitfalls mixed with blind optimism, but it seemed to go really well. Touch wood. Maybe there's so many chopped Pops around cos they're so easy to do. All the magazines mention cutting the roof into 4 or 6 sections, leaning pillars backwards or forwards etc -not just cutting it & plonking it back in place again. Of course, we only had half a roof to do.
-So how did you go about it then?


Title: Re: Manky's Pop.
Post by: Firery Fred on November 06, 2007, 07:43:53 PM
Sure will matey


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 07, 2007, 12:40:12 AM
here yuhs go Manky :) saw this on ChopperBuilder forums :)
http://cgi.ebay.co.uk/Vintage-Chrysler-Side-Valve-Engine-and-Drive-Train_W0QQitemZ200169164876QQihZ010QQcategoryZ100909QQssPageNameZWDVWQQrdZ1QQcmdZViewItem


Title: Re: Manky's Pop.
Post by: tazet on November 07, 2007, 07:12:17 AM
Looks like you boys had a good day. Sorry I was not there to make T's. I see Lunatic braved the cutter while everyone else pinned down the frame to stop it bouncing accross the yard  ;D
I agree with the black paint with red pin striping and the same would be good for the interior cose brown rustic would look odd. Maybe just get covers for the seats, (black with red piping) and sew on some Manky patches.
So whats the plan for the next day we spend down at Lunies workshop?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 07, 2007, 05:19:11 PM
I've got a brown bakalite dashboard from a Prefect & a brown steering wheel, (possibly original Pop. Not sure). It'd be sacrilege to paint the dash but possible I suppose. Providing they don't clash I think a black interior with the black paint would work best with just a hint of red -red piping on the door panels, rather than on the seats. If we're going with glossy black paint outside then the interior needs upgrading from tatty & well worn brown to much smarter black. I want to push on with the body at least before the Winter weather gets here. Can't put a floor in it till we know what's happening with the chassis, but the final welding of the roof can be done, with the tops of the rear pillars being moved back to line up with the bottoms as we said previously. The sills can be repaired & fitted & the bottoms of the A posts repaired. Then the doors chopped & bolted back on. That'll keep us busy for a while!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 07, 2007, 06:05:31 PM
guess you didnt like the look of that engine then?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 07, 2007, 06:54:05 PM
Thanks for the post VB, but nah, not quite my thing. The Consul engine was attractive cos it was a 50s Ford, the same as the car. Looks like it's gonna be the Rover V8 now though.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 11, 2007, 01:22:11 AM
Got lots to do this weekend so only managed an hour or two at the workshop today. Long enough to cut one of the rear door pillar tops off the roof & tack-weld it back in it's right position. Cutting into the guttering revealed acres of body filler -& very little metal. This rot will all have to be cut out & replaced with fresh sheet steel. A laborious process but worth it in the long run.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 11, 2007, 01:24:24 AM
Somebody had spent a fortune on body filler for this car.


Title: Re: Manky's Pop.
Post by: panthershaun on November 11, 2007, 08:17:18 PM
Check my Pop's post manky ;)


Title: Re: Manky's Pop.
Post by: BikerGran on November 11, 2007, 09:56:52 PM
Looks like it would be easier to dump it all and construct something new!


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 11, 2007, 11:10:09 PM
I reckon by the time we've finished, the windscreen surround will be the only original bit left!
Yours is looking great Shaun -but mine'll be prettier!
Had a look at Valley Gas Speed Shop's gasser style Pop last night.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 11, 2007, 11:57:43 PM
hmm loads a money there :)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 11, 2007, 11:58:59 PM
hmm Manky are u binning yer wngs ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 12, 2007, 05:33:53 AM
Yup -well I would if I had any. The 50s hotrod look means it's gotta be fenderless but I'll be running small cycle guards instead.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on November 12, 2007, 10:58:51 AM
 :o take a magnet with you next time eh ?


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 12, 2007, 11:14:00 AM
um so there gone already ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 12, 2007, 08:13:35 PM
Not so much gone, as never there in the first place VB.  :) Mine didn't come with any fitted. I share Shaun's view that 50s rods should be fenderless -stripped down to just the basics. If you happen to be looking for a pair of genuine steel Pop front wings, (why?), Shaun's still got his as far as I know.
I knew the filler was there when I bought the car Doc -the gutters were literally filled up with the stuff, so had half planned to de-gutter it anyway. I chatted to Shaun earlier today & he tells me his is just as rotten as mine. Fortunately, with only half a body, we only need to do half as much remedial work. Frustrating cos I want to plough on & get the body finished, but obviously it's worth cutting out every last inch of rot & repairing it now, rather than having to do it later, when it's finished.
I'm not forsaking my trike to play with the Pop, but as it's taking up much needed space in Lunatic's workshop, I've got to push on with it cos I don't want to outstay my welcome!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 12, 2007, 08:17:13 PM
the pop wings  i just wanted to experiement with them see how with alterations they might look as mudguards on the trike :) thats all. i to belive hotrods should be mudguardless :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 12, 2007, 09:14:50 PM
An expensive option -a pair of gennie steel wings will set you back the best part of 300 quid. I've seen Beetle ones used as trike guards with the headlights still in them. Certainly different.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 12, 2007, 11:14:46 PM
thats why i was asking if you pair were binning them :)


Title: Re: Manky's Pop.
Post by: panthershaun on November 13, 2007, 10:47:07 AM
mine sold I'm afraid, had no use for them or storage space ::) ::) ::)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 13, 2007, 11:16:18 AM
ok np was worth an ask


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 13, 2007, 01:16:35 PM
The new cab's a ...erm, snug fit. ;D


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on November 13, 2007, 04:30:49 PM
is that a genuine flinstones model ,mank ? ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 13, 2007, 08:55:10 PM
 ;D It's about the same age, yeah.
Not planning on fitting luxuries like a radio or heater. With Taz & I sat in it in the Winter in thick sheepskin flying jackets it's gonna be very cosy.
I was thinking about the colour scheme today while I was plodding the streets delivering the mail- definitely going for black now, rather than the green I'd originally planned. It just looks right. I want to do the interior in black too, with maybe red piping on the door panels to break it up a bit. I've got a brown Bakalite dashboard & brown steering wheel & they're going to clash with the black. I could weld in a plain steel dash panel & spray it black -or I could paint the Bakalite one. Seems sacriligeous to do it, but maybe worth doing for that very reason! Lunatic suggested doing it in candy or flake red so the Bakalite patterning shows through it. Will probably put the brown steering wheel aside & go for a repro black one instead. Saw some nice 4 spoke vintage tractor ones at the Dorset steam fair a few months back. I've half wondered about panelling the whole interior in polished aluminium, but it'd be like sitting in a microwave oven in the Summer! Or maybe we could turn the finished body upside down & do the whole interior in bright red metalflake!
A little more progress this evening. We chopped the top off the doors & bolted them back in place. Once they've been tweaked a little to line up properly, we'll tack weld them in place so we can continue cutting out & repairing the gutter rot. Closer inspection of the doors shows they've both been repaired, one with a large amount of fibreglass -so that'll need sorting too. We've added a small patch at the back edge of each gutter just to hold everything in place, & will work our way forward from there.  


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 13, 2007, 09:00:17 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 14, 2007, 09:39:28 PM
Another half hour's work on the Pop jigsaw tonight. I folded a couple of short lengths of 20 gauge sheet to take the place of the buggered guttering & Loony tacked them in place. We'll inch our way along the gutter line, cutting out & tacking in, not fully welding anything until it's all had a final tweak to line it up perfectly.
I don't want to use body filler & Lunatic's keen to try some lead filling so that looks the way to go.
The repair work's frustratingly slow -I wanna do the big stuff that makes it look like it's nearly finished! -but it's got to be done.   


Title: Re: Manky's Pop.
Post by: panthershaun on November 16, 2007, 10:19:48 AM
coming along nicely mate, will look good when finished. Can't wait to get them side by side at a show someplace ;D ;D ;D ;D
just been looking at my 2 CV's rear seat, might make a good bench for the Pop ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 16, 2007, 10:35:20 PM
I used an Allegro rear seat as a bench in my Moggy Minor pick up years ago. Black velour with fold down arm-rest. Would have to be leather for a Pop though I think. Think I'll probably stick with 2 seperate seats in mine -mainly cos I think the V8 gearbox tunnel's gonna be quite high. I sold Loony a pair of repro Austin Chummy seat frames a while ago for his Volksrod. They'd look pretty cool, powder-coated metallic silver to look like aluminium bomber seats. Maybe just buy new black covers for the original Pop ones.
If you're going for a bench, how about covering it with a Mexican blanket, as is the current trend with rods, but have it properly upholstered -Mexican blanket tuck n roll.


Title: Re: Manky's Pop.
Post by: panthershaun on November 16, 2007, 11:18:16 PM
Funny you should say that :D I have a genuine Mexican blanket at home that I purchased from a stall in Tijuana in Baja California years ago ;D ;D


Title: Re: Manky's Pop.
Post by: lunatic on November 16, 2007, 11:19:32 PM
Manky and I were only talking about that a few hours ago! 8)


Title: Re: Manky's Pop.
Post by: panthershaun on November 16, 2007, 11:24:10 PM
what??? my Mexican blanket >:( >:( >:( I knew I shouldn't have let you use my toilet >:( >:( you must have had a good look around :P :P :P :-\ :-*


Title: Re: Manky's Pop.
Post by: lunatic on November 16, 2007, 11:28:27 PM
Mexican blankets in general!! I havent been snooping round your loo! Honest ;)


Title: Re: Manky's Pop.
Post by: tazet on November 17, 2007, 07:47:44 AM
What else are we supposed to do when the door sticks and you can't get out  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 12:18:06 AM
Mr Lunatic & I spent the afternoon de-guttering a bit more of the Pop. The rust appears to end halfway along the door tops, with the front section being pretty solid, which'll save us some work. We decided to re-install the top half of the door frame & build up the body to suit, rather than trying to make the door fit the hole we create. Dropping the door height by 3 inches means the frame has to move forward to line up again, leaving us a small section to fill in. Shouldn't be a major problem.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 12:20:39 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 12:28:58 AM
The door's temporarily tacked to the body again to hold everything in position while we work on the guttering. We weren't sure how it'd look minus the gutter rail, but with some patient metal bashing by Loony it should have a nicely rounded shape -like me :)
The rear corners of the door tops will be radiused -an arc cut off the door frame & welded into the body to make them curvier.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 12:33:36 AM
The side windows are now roughly 10 inches tall, with a 7 inch windscreen. I'm not gonna see the sky very often driving this thing. Enough room to get my elbow out the window though, for that all important cruising stance.
We seem to have somehow become left hand drive!


Title: Re: Manky's Pop.
Post by: brock on November 18, 2007, 12:41:53 AM
   I've never noticed the difference in glass height before, bit late now but you could have cut the screen suround out , chopped the shell and let the screen back in higher in the roof line to level the tops ( isn't there always one, after the event ! ) Doesn't the piece out of the rear of the door fit the top too ?
   Looking good by the way


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 12:49:35 AM
Now you tell us!
Nah, I like the shape as it is. Chopping the pillars is one thing, but wouldn't want to disturb the actual roofline. Yep, we've carefully stored the section from the rear upright to fill the gap at the top of the door, (O.K, we slung it on the floor, but we know where it is when we need to retrieve it). Still a fair bit more tweaking required to get the 2 door top sections to line up perfectly & Loony's hammering away at the gutterline to get it to flow nicely.
I'm pleased with it so far.  :)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 18, 2007, 11:44:13 AM
cracking work Looney bet yer glad to have that helper Manky with you :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 10:33:32 PM
Not much of a help at the moment. I can cut slips of plate to bridge the gaps & hold them in place while Loony tacks them, but the rest is really a one man job. Very frustrating cos I want to forge ahead, but time spent here will be well worth it when it's finished.
Had a call from Shaun this afternoon to say he & Grizz were giving up for the day, having been working outside on his Pop in the freezing cold since early this morning. We were still standing around the heater in Loony's workshop, drinking tea, munching choccie chip biccies & getting ready to make a start.
The front of the door top was taken out again, adjusted a little more with the grinder & put back in. That's better. The joint in the top of the window frame lines up better now. The section cut from the rear upright was re-used to fill the gap. It needs a little fettling, but it's almost right.
Then we removed the last of the gutter & tacked in fill-in strips of fresh steel. As I said yesterday, the front end of the roof's pretty solid, so the new steel can be blended in to run down into the front door pillar quite nicely.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 10:38:20 PM
The sharp corner at the back edge of the door was softened by radiusing it -cutting an arc off the door & welding it into the body shell. A small detail but it helps with the overall curvy shape of the cab, emphasising the flowing lines of the gutterless roof, & will hopefully echo the curve of the Moggy Minor roof section. Seems to make the car look more vintage too -like a 50s Yank truck.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 10:41:34 PM
Kinda busy this week as I'm moving house on Thursday, but we'll be back at the workshop on Tuesday evening.


Title: Re: Manky's Pop.
Post by: Chevy Rick on November 18, 2007, 10:52:46 PM
50s yank truck, steady on Andy  ??? gutterless bodys one thing i found with a Camaro every time you open the door when its raining it drips in on you or pours inside :-[


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2007, 11:12:40 PM
Mr Lunatic Senior's got a Pontiac Firebird stashed away round the back of the workshop. That did exactly the same thing apparently. Reaading the Pop Parts Plus & Pop Browns catalogues, there seems to be 3 or 4 different pieces of rubber seal & trim that make up the door seals. Unfortunately the previous owner of mine has "repaired" the door opening & plated over the channels the rubbers sit in. Hopefully we can rework them & get a vaguely waterproof cab.


Title: Re: Manky's Pop.
Post by: lunatic on November 19, 2007, 04:52:55 PM
Passenger side is all welded and ground down. Start on the drivers side tomorrow evening then.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2007, 05:10:23 PM
Woo hoo! Thank you Sir. A slow day on the VW front was it?  ;D


Title: Re: Manky's Pop.
Post by: lunatic on November 19, 2007, 05:17:19 PM
Was waiting for some bits to turn up and I couldnt help but grind down the welds! Its much neater now!


Title: Re: Manky's Pop.
Post by: panthershaun on November 22, 2007, 10:35:00 AM
Looking good guy's, love the door top.

Really jealous of your workshop Loony  :'( :'(
I think our 2 pickups are going to be SO different don't you think ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 22, 2007, 01:33:44 PM
Hope so! We're building custom cars, not kit cars. ;D
Wouldn't it be boring if they turned out identically. I think they're both looking pretty damn cool!
We're off to pick up the Rover V8 for mine on Sunday.  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on November 23, 2007, 08:56:31 AM
too right, mine is going to look like a mildly hotrodded standard truck (I hope) whilst yours is going to look like a full on Hotrod, am I right ???


Title: Re: Manky's Pop.
Post by: lunatic on November 23, 2007, 04:44:52 PM
With a little flexibility you can just get in it! The video of me getting out throught the window is good though! ;D
What are we using to pick up the V8 in?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 23, 2007, 10:51:25 PM
Lookin' good Loony. :D
The guy with the V8 has a Transit pickup & says he can deliver it -to my lock up for the time being?
He owns a Granada & took a V6 out of it to fit the V8, which came from a Standard 8 drag car, (although I don't think it's race tuned). Then a Cosworth lump came up so he fitted that instead & the V8's been sat in the garage ever since.


Title: Re: Manky's Pop.
Post by: brock on November 23, 2007, 11:05:08 PM
   along with a Standard steering box ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2007, 09:25:40 AM
 ;D I'll ask!
The motor was removed 4 years ago so I'm guessing the drag car's long since gone or been fitted with something else.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2007, 10:01:00 PM
No steering box I'm afraid Steve. Just the engine & box sat on a trolley in the guy's garden.
Looked pretty good. Turned over nicely & made nice wump, wump wump noises, but the owner couldn't get it to fire. It had a weird connector block in the ignition circuit that no-one could figure out. I think I'll definitely buy it but I'll wait till the guy who took it out of the car can come over in a couple of days & fire it up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2007, 10:19:27 PM
After we'd been to see the engine, Loony & I got to work on the cab back.
On PantherShaun's recommendation, I bought a 1970s Morris Minor cab back panel from a Brit Chopper forum member in Wales. Cost me 20 quid & had some major rot in the bottom half, but we weren't planning on using that bit anyway. We cut it off level with the waistline on the Pop. The Moggy panel's a couple of inches narrower than the Pop so had to be cut & widened somewhere. Cutting it straight down the middle would mean having to have a new rear window specially made. Cutting it either side of the window opening means the standard glass, (which I've got), will go right back in.
Mr Lunatic started by tacking the centre section to the Pop roof in the middle then working out either side, pulling the 2 roofs together & tacking to create a nice flowing curve. The Pop roof's now got a nicely rounded profile, instead of being dead flat as it was before.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2007, 10:26:07 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2007, 10:27:07 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2007, 10:32:06 PM
Then the sides were tried in place. Not bad. A little massaging & they'll do nicely. That'll leave an inch wide strip to add in either side of the window.
Lookin' good. For half a car with the back of a car 20 years younger slapped on, it looks right.
Nice work Loony. ;)


Title: Re: Manky's Pop.
Post by: mouse on November 26, 2007, 09:13:36 PM
thats looking good m8


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 27, 2007, 10:20:28 PM
It'll look better with me cruising in it!  8)


Title: Re: Manky's Pop.
Post by: mouse on November 28, 2007, 08:31:45 AM
It'll look better with me cruising in it!  8)
nahhhh ya got that wrong m8 it would look even better with me cruising in it  ;D ;D pmsl


Title: Re: Manky's Pop.
Post by: panthershaun on November 29, 2007, 10:22:03 AM
Good work guy's, looks the bollox already  ;D, see I told you it would fit  :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2007, 08:09:01 PM
I've never figured out why B*llox should be a compliment.
There's more filler on the roof than we originally realised & what looks like factory lead filling too. Seems to be 2 joints in the roof, one at either end of the door, identically placed on both sides of the car, that've been filled with lead. We can't weld to that & it melts away to nothing as soon as you wave an oxy torch at it. So Loony will plate over the deepest areas & we'll try our hand at leading the rest. Have you got the same joints in your roof Shaun, or is ours an early cut & shut job?   


Title: Re: Manky's Pop.
Post by: mouse on November 29, 2007, 08:21:21 PM
was the original vinyl section taken out of the roof by you manky ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2007, 08:39:50 PM
No, already done when I bought the car. A tidy job, not bodged. The joints in the roof are only in the original section that runs around the outside of the insert & are quite deeply V'd. Even if it were the result of old accident damage, it doesn't matter as we're virtually rebuilding the car from scratch. We're just curious that's all. I'll try & get a photo of them.


Title: Re: Manky's Pop.
Post by: mouse on November 29, 2007, 08:46:22 PM
OK m8
i did some research years ago about ford pops/Anglias and the results i got was. What ever they had to hand was what got fitted at that time lol
they adjusted the doors with bits of 3"x2" wood lol


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2007, 08:56:35 PM
 ;D Yeah, that's the impression we've got! Wonderful stuff!


Title: Re: Manky's Pop.
Post by: panthershaun on December 08, 2007, 10:54:34 AM
any progress???


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 08, 2007, 12:38:13 PM
No, 'fraid not.  :(
Lunatic's been ill this week with a flu bug thing, plus when he's been O.K to work, he's needed to get on with paying customer's cars. So the Pop's had to take a back seat for a while, (if anyone wants a Pop back seat I've got one by the way!). The pick up body's all just tack-welded at the moment with everything still subject to change if necessary. It's a patchwork of small fill-in pieces of steel sheet. Loony's taken the rear cab-back corners back off & repositioned them a couple of times, trying to get a perfect curve to match the original Pop roofline. The centre section of the Moggy cab back's still got it's strengthening flange, (where it used to bolt to the Moggy cab), which helps to keep it's roof shape. We've taken the flange off the corner sections though so they can be pulled about to meet the original Pop panels. Next job is probably to repair & replace the sills under the doors to tie the whole cab unit together into one piece & give it some rigidity.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 09, 2007, 07:29:39 PM
The heart of the beast.
My newly acquired 3 & a half litre Rover V8 engine & auto box. Up & running & bought for 200 quid from a friend of a friend here in Basingstoke.
Vroom, vroom! ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2007, 01:09:27 AM
Thanks to some research by Brock we now know the motor came from a 1979-80 SD1 Auto Rover with 9.35:1 compression. Mind you, there's no guarantee the heads came from the same motor. The guy I bought it from seemed to think they were from another model. They're wearing Range Rover exhaust headers, which are more compact than SD1s, so he may be right.
I don't intend playing about with the motor too much, just a quick tidy up & fix any leaks, then bung it in. If it ain't broke, don't break it by trying to fix it.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on December 10, 2007, 11:45:57 AM
that trike would look nice with mudguards on mank......... ;D ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2007, 12:30:47 PM
It'll get them, don't worry!
Gonna buy some new rear tyres cos mine are too old for the MSVA -I'm told they've got to be 5 years old or less & according to the date code on mine they're 18 years old! Absolutely nothing wrong with them though, loads of tread & no sign of the sidewalls perishing, so I'll keep them as spares. New tyres might solve the mudguard/tyre clearance problems. Unlikely but you never know. It'll give me a better idea of exactly what size spacers I need to have made anyway.
Then the mudguard struts can be trimmed to length, mounts for side marker lights added to the open tube ends, then indicator mounts & the mounting holes for the guards themselves of course. After that, the struts need drilling for the wiring & powder-coating in gloss black.
Then they'll be fitted!


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 14, 2007, 09:41:46 PM
Well, my Pop's all finished & on the road. Looks O.K don't it.


...............I wish.  :(


Title: Re: Manky's Pop.
Post by: brock on December 15, 2007, 12:47:28 AM
yeah, just OK though, you should have arched that rear screen if you were going to use such a heavy belt line. Did you see the other shots of it, same gallery.


Title: Re: Manky's Pop.
Post by: panthershaun on December 15, 2007, 08:38:03 AM
very nice Manky mate, agree with Brock ;) :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 15, 2007, 05:22:06 PM
Sigh.
O.K, I'll do it again.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 15, 2007, 10:22:09 PM
Called at Loony's workshop this afternoon after work. PD was there too. The boys were hammering my Pop, cutting & tacking in the filler strips either end of the cab back. Lookin' good chaps.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 15, 2007, 10:29:01 PM
A fuzzy pic but it shows just how much we've changed the profile of the ol' Pop -for the better? I was berated at work this morning for cutting up a classic car. Tough! It's mine & I like it!
Dodgy looking pair lurking next to it though.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 15, 2007, 10:37:54 PM
I made myself useful by cutting out the rotten ends of the original Pop sills & making new repair pieces. Loony will weld 'em in place & bash 'em into shape. They're deliberately overlength so they can be trimmed back once fitted to suit the new body shape.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on December 16, 2007, 02:28:28 PM
nice work Gents :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 19, 2007, 10:36:02 PM
Bugger.
Had a letter from the DVLA today. I'd sent off the Pop's logbook & changed the body type from saloon to pick up, plus changed the engine details. They've told me they need to inspect the vehicle before they can issue a document.
The DVLA have been tightening up their act for the last couple of years -seems the days of slipping seriously altered vehicles through the system undetected are over.
So- I've now got to build my Pop to SVA standards. Bugger.
I've read on other forums that the commercial vehicle version of the SVA test is much simpler than the normal car version. Even so, it's a daunting prospect. I need to start looking into it all.
Worst case scenario- it'll still get built. If I can't meet the regs, I'll take it drag-racing instead! 


Title: Re: Manky's Pop.
Post by: mouse on December 20, 2007, 09:48:19 AM
 >:(the miserable sod try to take the fun out of everything don't they
good luck with it all m8


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 20, 2007, 05:07:39 PM
Better to be legit in the long run I guess.


Title: Re: Manky's Pop.
Post by: lunatic on December 20, 2007, 06:54:05 PM
Well in that case we might as well put a new chassis under it! ;D Did they say it needs to be SVAed or just an engineers report?

In the long run it would have to be inspected as the mot testers are being told to report anything with modified chassis/ suspension, might as well do it now rather than later.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 20, 2007, 10:05:24 PM
True. I really need to talk to someone & find out exactly what's what. If it's just a matter of it needing to keep it's original chassis to qualify as the original vehicle, & I'm allowed to change the engine & suspension, then it's not a problem. Would just mean I couldn't "Z" the chassis as I'd planned. If, however, any deviation at all from standard requires a full SVA test, then we've got nothing to lose. I'm sure I read a thread somewhere on the NSRA forum about a pick up that had passed SVA despite arriving without engine, glass, interior & a million other bits.
I'll wait till my local licensing office contact me to arrange an inspection & ask them where I stand with it all.
-Don't let that stop you working on the body though mate!  ;)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on December 21, 2007, 12:25:37 AM
Sooze over at BritChopper is s**t hot on bike /trike related svs mvsa stuff i reckon Sooze would know about hotrods too? maybe worth an ask any rds :)


Title: Re: Manky's Pop.
Post by: panthershaun on December 21, 2007, 10:54:01 AM
I'll ask for you Manky, as I will need to know as well.But I do think it is modified at all, including axles, brakes etc sod sod sod  >:( >:( >:(


Title: Re: Manky's Pop.
Post by: TwistedPatience on December 21, 2007, 07:31:33 PM
You could tow it behind the trike eh!


Title: Re: Manky's Pop.
Post by: BikerGran on December 21, 2007, 07:37:09 PM
There is - or used to be - a points system for deciding whether a vehicle can keep the original registration, but basically it means it need to keep about 3 out 4 main parts, ie frame (or chassis), engine, wheels, suspension.  That's how come my trike has the old reg no, as really only the swingarm is modded.  Don't think yours will qualify for that!


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on December 22, 2007, 02:29:57 PM
i think that you just notified them of too many major changes ,should have done it gradually .


Title: Re: Manky's Pop.
Post by: tazet on December 22, 2007, 02:36:06 PM
He only put engine number and changed body style and nothing else. He had to send the V5 off to change the address on it when he moved.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on December 23, 2007, 09:09:39 AM
yea,but what i meant,was,notify changes one at a time,ive done it recently with a chop,changed the engine number,then,later on changed the chassis on the book.


Title: Re: Manky's Pop.
Post by: tazet on December 23, 2007, 09:59:53 AM
Oh well. Bit late now  :(


Title: Re: Manky's Pop.
Post by: mouse on December 23, 2007, 10:07:53 AM
Oh well. Bit late now  :(
Good Morning Tazet cold aint it m8


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 23, 2007, 10:42:28 AM
Yeah, I've always changed details over bit by bit like that, but the system's just getting tighter & tighter now. If it didn't get picked up straight away it'd probably get flagged up when I tried to MOT it, or, God forbid, if I ever had an accident they'd declare it illegally registered. I'll look into the SVA situation. My brother, Brock, keeps telling me it's the way to go & not as tough to pass as it's made out to be -same as ByzMax says about the trike MSVA. I'd rather be completely legit & not have to worry about being pulled.
It'll be a challenge to build to the regulations!


Title: Re: Manky's Pop.
Post by: lunatic on December 23, 2007, 12:15:41 PM
If you change the body style of a car from, say a saloon to a pick up, they will ask for an engineers report. Its been like that for years. I guess to try and stop the ' I chopped the ass off my car and replaced it with a packing crate, now its a pick up' people.
I think building to msva regs is a challenge, but worth it as more people will get picked up at mots and have to re register and sva test their cars.
The points thing is to keep the vehicles identity. You can keep the original plate if you have a certain amount of points, As we only have half the body and some of the chassis that will remain unmolested, I think a Q plate will be on its way! ;D But a Q plate doesnt matter anymore as the dvla are going to try and get all modified vehicles on Q plates eventually. This way everyone involved with the car, mot testers, coppers etc, will know its modified. Not really a bad thing, as the testers will know to look for mods and that they are done safely.


Title: Re: Manky's Pop.
Post by: BikerGran on December 23, 2007, 01:46:32 PM
Also when buying a vehicle that's on a Q plate you will be more able to feel confident that it's properly registered.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on December 24, 2007, 12:40:24 PM
Q-plate,ive only been offered 3rd party only insurance in the past,might be different now,it was a while ago.
you should have no problem with test mate,from what ive seen and read,you build things properly and safely anyway.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 24, 2007, 11:29:57 PM
I think I need to find someone who's put a vehicle through the SVA before. Or get hold of a copy of the regs. Really wanted to get the Pop on the road for the Summer.


Title: Re: Manky's Pop.
Post by: brock on December 25, 2007, 12:34:19 PM
This is a Good Thing, it really should not be a surprise as the system is getting better all the time, getting a "friendly" MOT tester to ignore changes is also not happening as I believe it once might, as it is now their licence and livleyhood on the line. Furthermore, there are the beginings of dark rumours regarding classic, historic, or just plain old cars being held to a restricted annual milage. All of the forgoing and more points to SVA being the way forward. Now you get the chance to build a "proper" car, re-read all those articles I sent you on chassis design, bin that fifty year old 30 horse chassis and construct something fit for purpose. Join the NSRA, get the manual , contact Kev Rooney and talk it through, he's the premier available source of accurate information and would seem to be keen to promote proper builds. You've made such a cracking good start on it , it would be a shame to waste it all with substandard underpinnings. Again, as always , this is just an opinion and should be treated as such.


And Happy Christmas to one and all


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 25, 2007, 12:55:06 PM
O.K, let's do it!


Title: Re: Manky's Pop.
Post by: PD on December 26, 2007, 09:06:16 AM
sounds good 2 me!!
u should always listen 2 your big bro Andy!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 27, 2007, 12:24:27 AM
I always do -eventually.


Title: Re: Manky's Pop.
Post by: lunatic on December 27, 2007, 06:47:04 PM
 ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 28, 2007, 10:50:17 PM
Loony's still plugging away at the sheet metalwork on the cab back. Getting there.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 12:51:34 PM
The two cab back corners are now in place, with filler strips added. The right-hand bottom corner was rotten so that's also been replaced with fresh metal.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 12:59:15 PM
On either side, towards the front of the roof, are what look like factory made roof joints. These were filled with lead, (the fore runner of modern body filler). We can't weld to that so it all had to come out. Easiest way was to melt it out with the oxy-acetelane torch. That's my car you're setting fire to Loony!  :o


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 01:16:06 PM
Pops were originally fitted with a vinyl roof insert. This is a 1953 car & steel was in short supply after the war, so Ford used a vinyl panel, stretched over wooden spars as a steel-saver. The first thing modern Pop customisers do is replace that with fresh steel, usually taken from the roof or bonnet of a newer car. We thought my roof had been very nicely filled, but once we started digging into the thick layer of filler around the gutter line, we discovered the new panel had been laid over the original roof edge & the resulting step smoothed out with filler.
After some discussion, we've decided to take a deep breath & cut it back out, set it in flush with the roof & weld it back in. It needs a bit of bashing anyway cos it's a completely flat panel, whereas the roof curves across it's width. We'll probably add some curved steel strips under it to help keep it's shape & add extra strength.  


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 01:40:18 PM
At that point we thought, bugger it, might as well sand all the paint off so we can see just what we're dealing with.
Cue Taz the crazy lady. Give her an angle grinder & a sanding disc & she'll sand anything that stands still long enough.   :P The workshop was soon filled with billowing clouds of filler dust.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 01:43:59 PM
Cough, cough, splutter.
Where'd everybody go?


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 01:47:57 PM
The sensible ones had all buggered off outside.
Long nights working in the garage on yer hotrod. I love it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 01:54:49 PM
By the time we've finished, there'll be very little original Pop tin left! The doors both need lower repair panels & the firewall will be cut out & rebuilt to accomodate the Rover V8 powerplant. Only standard area left is the windscreen surround -& even that's been lowered by 3 inches.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 02:12:24 PM
Loony usually works on VWs & had a couple of camper van repair panels in the workshop.
Hmm. I really like these. I don't want just a plain home-made looking box on the back. It deserves something with a little more shape & style. How about a pair of these, set back in about 6 inches narrower than the cab back to show off it's curvy rear? Add a tube frame along the top edge, so the panel curves inwards at the top to mimic the roof line. I'd like a flat ledge maybe 2 inches wide around it with an inner skin, rather than just a single panel thickness. The pick-up bed doesn't have to extend down to the bottom of the panel, just sit onto the rear chassis rails, with outriggers holding the bottom edge of the panels.
The wheel's a spare for the boys' trike, sat in an old tyre from Loony Senior's Pontiac. Not what I'm fitting but looks kinda cool anyway. I'm going for 50s style tall n skinny truck tyres on painted 16 inch steel rims.
I reckon I can use these camper van rear arch panels with the wheels sat outboard of them, covered with black powder-coated ally cycle guards.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 02:17:05 PM
Of course, we could go pro-street instead?


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 02:19:18 PM
Can't wait to fire this up & go cruising!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on December 30, 2007, 06:33:36 PM
looks fcking brill so far :) and them van panels look kewl as :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 07:17:25 PM
Thanks Gareth  :D
Would be a shame to put all that effort into the cab then waste it by bunging any old box on the back wouldn't it. Not planning on building a show winner, but if we're doing it, we should do it right I think.
Still waiting to hear from the local vehicle inspectorate -if we're very lucky, the finished truck might just need an engineer's report before they'll hand out the logbook. If not it'll have to meet the SVA regs. Either way it'll be as pretty as we can make it. :)


Title: Re: Manky's Pop.
Post by: brock on December 30, 2007, 07:28:04 PM
   I like that outer panel, really like it, set it up properly with a set of steels inside and step back, have open wheeled pickups been done to death ? can you be brave enough to be different ? rear corners off of a type two will already be rebated for the tail gate which could be "floating" on cantilevered hidden bottom hinges, deep tunneled '59 Caddy lamps with just the tips protruding, narrow tubs inside with a pair of fuel tanks (one each side ) between the cab and the tub and all covered by the inner skin, all too easy with someone elses toy, what do you have in mind ?  


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on December 30, 2007, 07:43:25 PM
i want brocks brain :)


Title: Re: Manky's Pop.
Post by: brock on December 30, 2007, 07:56:10 PM
   make me an offer mate , we're developing a serious methanol habit and the new motor should be ready to ship in August , everything must go !


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on December 30, 2007, 08:04:13 PM
i like methanol i used s**t loads of it where i used to work,its a carsonjenic thing :) though so watch it :)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on December 30, 2007, 08:05:16 PM
do u do board and lodge ? :)


Title: Re: Manky's Pop.
Post by: brock on December 30, 2007, 08:34:12 PM
   sometimes do bored and fractious


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2007, 08:50:58 PM
Care to do us a sketch of your ideas Brock?
I'm after trad' pick up with enough originality that it doesn't follow the herd, without going too high tech & modern. It's got to be a daily driver too.


Title: Re: Manky's Pop.
Post by: brock on December 31, 2007, 10:09:11 PM
   this is proving problematical, I'll play with it some more but every time I get close to something I like I seem to need to add a sort of streamlined teardrop sort of thing to the back edge of the front mudguards, it's all gone kustom on me !
   As an aside I was looking for type 2 panels when I came across this , have fun...

                                http://www.busselecta.com/bus/


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 31, 2007, 10:48:06 PM
 ;D Hours of fun!
Bear in mind the Sherpa axles I've got are about 6 inches wider than the orignal Pop ones & I really don't fancy trying to narrow that front beam, or the rear for that matter. So it's gonna be wheels outside the bodyline -unless you can come up with something prettier?


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 03, 2008, 12:29:52 AM
I called in at Loony's workshop again on my way home from work today. There's really not much I can do on the bodyshell at the moment -it's down to Loony's panel bashing skills to pull it all into shape. So I contented myself with cutting a repair patch ready for him to weld in place, then mocking up the pick up bed to see how it'd look.
These are the VW camper van lower rear repair panels. I think they're about 20 quid each. The actual arch is roughly the same width as the tyres I'll be using so the axle will be set centrally in the arch. I slid the panels into the back of the open cab until the length looked about right. We'd wondered if we could use the camper van rear corners too, but when we tried one we found it's curve was too sweeping -extending the back of the bed almost another foot. Too long. So Mr Lunatic will probably roll a simple tight, single curve around the rear corners & not worry about trying to produce a double curve that sweeps under the bed too.
Loony & I agreed the pick up bed should be roughly the same length as the cab unit &, if possible, slightly shorter than the bonnet. I'd forgotten how long & pointy the Pop nose is. I dug out the relevant panels & propped them in place. The front end measured 120cm. The pick up bed I'd mocked up came to 100. Perfect. That'll make quite a useable load area -roughly 3 foot 6 long by 4 foot wide.
The VW camper floor's also available as a repair panel & has cool, semi industrial looking ribs pressed into it, which would look good.
O.K, so it's nothing stunningly original, but we can make a nice, tidy looking trad' pick up. Maybe it's been done before, I dunno, but it's the first one I've ever done & that's all that matters.  :)
Any opinions?


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 03, 2008, 12:31:13 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 03, 2008, 12:35:49 AM
With the Rover V8 in place, we'll probably have to push the front axle forward a tad, but I don't want the front spring perch ahead of the radiator shell -don't want to interrupt that long front panel cos I think that's the defining shape of a Pop.


Title: Re: Manky's Pop.
Post by: lunatic on January 03, 2008, 07:54:14 PM
You gotta love it!! 8)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 03, 2008, 08:00:42 PM
Ready to go with it when you are matey! :)


Title: Re: Manky's Pop.
Post by: brock on January 03, 2008, 08:15:39 PM
   gets very noisy in that tea shop does it ?


Title: Re: Manky's Pop.
Post by: lunatic on January 03, 2008, 08:36:42 PM
   gets very noisy in that tea shop does it ?
Yeah, theres all these noisy buggers welding and grinding and the like! So inconsiderate! ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 03, 2008, 08:52:29 PM
Oi, that's not sugar in me tea, it's grinding dust.  >:(
Nothing worse than gritty cucumber sarnies.
Taz remodelled Loony's office as a tea room, complete with serving hatch, & it seems to have stayed that way. Pops & Pot Noodles. Perfect.


Title: Re: Manky's Pop.
Post by: BikerGran on January 03, 2008, 10:53:47 PM
Haven't seen your trike thread updated lately........  in fact I can't even find it!


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 04, 2008, 04:55:44 AM
It's slipped down to page 4 of General Discussion Bobbi.
Don't worry, it's still on the go, just very slowly. I'm dropping some parts off at the powder coaters when they re-open next week. You could do me a favour actually. Is the MSVA guy still posting on the 100% Biker forum? If you still visit there, I need a contact number for him, to check a few points on the trike build.


Title: Re: Manky's Pop.
Post by: panthershaun on January 04, 2008, 11:20:27 AM
I'm liking that Manky, liking it lots :D :D :D the only thing that is worrying me about your build is the width of the axles, can you get a picture of her with an axle roughly in place so that I can see what it looks like as 6 inches is a fair bit wider than the old stuff :-\ :-\ :-\


Title: Re: Manky's Pop.
Post by: brock on January 04, 2008, 12:00:26 PM
   just as Shaun said, I was trying to find one to measure before posting but I also think you might be in for a little bit of work there


Title: Re: Manky's Pop.
Post by: lunatic on January 04, 2008, 01:33:41 PM
I think we might need to narrow the back axle and dare I say it, it may be easier in the long run to ditch the front axle off the sherpa and buy a new I beam or drop tube axle. Im worried that it will ride too high on the front as we can only kick the frame up so high and the axle has no drop in it at all. And no you cant have any pics of the axles in place cos we buried them down the side of the shop behind the remenants of the pop!


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 04, 2008, 04:20:04 PM
If Mr Lunatic's at his workshop over the weekend I'll try & get over there to dig an axle out from it's hiding place under a small mountain of car parts. 6 inches wider means only 3 inches wider each side, so not hugely oversize compared to the original. I'd still like to go with the disc braked Sherpa front beam if possible -a new drop tube jobbie seems a needless expense really. I was trying to recycle all the bits I've got knocking about if I can. 


Title: Re: Manky's Pop.
Post by: lunatic on January 04, 2008, 05:06:20 PM
Ill be there. We will be painting though.
The only problem I see is that by my estimates the chassis will have to be at least 18" off the floor to use the sherpa axle hung below it. Then with the channel and the engine in I reckon the engine down to the exhaust headers will have to stick through the bonnet. Or if you mount the spring behind the axle and end the chassis before the axle you may have to run the engine so far back that you dont fit in the cab! Just my worries. ;D


Title: Re: Manky's Pop.
Post by: BikerGran on January 04, 2008, 05:16:11 PM
Is the MSVA guy still posting on the 100% Biker forum? If you still visit there, I need a contact number for him, to check a few points on the trike build.

I don't go to 100% these days but had a look just for you, and yes, Chris 'MSVA Tech' is still posting there.  There's no contact number that I can see tho it does say the contact number is in issue 60, if anyone has kept all theirs - mine all went went I had a clearout.

There's so much useful info in the very long MSVA thread that you should really go there yourself cos most of what you want to know has prolly already been covered.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 04, 2008, 05:18:14 PM
Hmm, a bit of measuring's called for I think.
Just checked my post -I've got a letter from the DVLA, telling me to drive my Pop to their Wimbledon office for inspection in 2 week's time! No answer on their phoneline so I've emailed them, pointing out that's not going to be possible cos it's in a million pieces undergoing restoration. I await their reply with interest.  :-\


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 04, 2008, 05:21:32 PM
Thanks Bobbi. Guess I'll have to steel myself to go back, though I swore I wouldn't. I need to know what type of brakelines are allowed & whether there's an age limit on tyres, as I get different opinions from everyone I ask.


Title: Re: Manky's Pop.
Post by: lunatic on January 04, 2008, 05:23:35 PM
Just go back as 100%hater or something ;D


Title: Re: Manky's Pop.
Post by: davesatan on January 04, 2008, 06:17:38 PM
chris number 01179542544


Title: Re: Manky's Pop.
Post by: brock on January 04, 2008, 09:19:30 PM
   by the time Grizz turned up this afternoon it was too wet, cold and dark to measure his axle, but parked next to the transit there didn't look to be much difference, I can put my spare Pop axle across the floor of the transit so I gues there is a bit more than 6" difference between them. Rear axles are narrowed all the time, a lot of early style dragsters use them, there's a fella in Birmingham that I can get a number for if you want a "race spec." job, front axles are also dropped with some frequency but you might want a bit of experience behind you before trying it, the HAMB have some good threads showing the jigs etc used. There is however, nothing stopping you building your own tube front axle and fitting all the Sherpa stuff to it, machine two king pin carriers the same size as the Sherpa axle ends and weld them in to a straight or dropped tube, probably a better option in the long run as you can place your batwings and spring hangers where they need to be rather than where dictated by the original, also give you the chance to set the camber and caster (KPI) to suit.


Title: Re: Manky's Pop.
Post by: BikerGran on January 04, 2008, 09:23:01 PM
Isn't all that sort of stuff in the manual?


Title: Re: Manky's Pop.
Post by: tazet on January 04, 2008, 10:12:46 PM
What manual?


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 04, 2008, 10:23:07 PM
Jeez, that's complicated Brock. Have I taken on more than I can handle?


Title: Re: Manky's Pop.
Post by: brock on January 05, 2008, 12:58:57 AM
  No, you've made a blinding start, it's just that now you need to make intelligent informed desicions about how you go forward, that means actually reading and understanding all that stuff I send you rather than just glancing at it and hoping for the best  ;). None of it is really that difficult in isolation it just seems a bit daunting as a whole, it is , after all, a complete car you are building from the ground up, a stack of stuff to be built or sourced and nailed together in something like the right shape. You're not the first to do it ( or reach that first realisation that it's a little bigger than you first thought) and the information is out there. Once again, join the NSRA and make use of their experience. I guess you might know my opinion on the chassis and that is one of the fundamental choices you need to make early on, so do it, then take a week out thinking about it. Take photos in profile of the body, wheels , bed sides, motor etc, take them all from the same distance (use a tape measure) and get down level with the bits for a true profile, then cut them all up and assemble the bits on a clean sheet of paper, get comfortable with what you are actually aiming for and when it's right scale the critical dimensions, axle centres, firewall,bed length, ground clearance etc. Do the same front and rear and get a feel for axle and bed width, all of this will start to plot your chassis which after all is just a way of holding all the bits in the right order. Give me a ring or come over sometime, I'll be the one sat in the truck wondering if 18 months into it, I might have taken too much on.


Title: Re: Manky's Pop.
Post by: panthershaun on January 05, 2008, 10:38:47 AM
Sorry Andy  :-[ I opened a can of worms. Its just that the rear of your pickup looks so right in the mock-up's
with the rear wheel sitting close to the pickup sides, move that out 3 or 4 inches and it may make the pickup bed look a little narrow. but until you mock it up its only a thought.
If you narrowed the Sherpa rear axle and ran the Pop front axle fitted with spitfire disc's on a suicide perch just behind the grill similar to this I think it would work as this guy has a V8 fitted and this is using a standard chassis.


Title: Re: Manky's Pop.
Post by: BikerGran on January 05, 2008, 03:34:51 PM
What manual?

The MSVA Manual

Sorry, this is nothing to do with the Pop, it was about the trike!

Quote
I need to know what type of brakelines are allowed & whether there's an age limit on tyres, as I get different opinions from everyone I ask.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 05, 2008, 03:50:08 PM
 ;D Just thinking aloud at this stage Shaun & trying various options.
The Sherpa axles were intended for the '27 T hotrod body I had last year, which never got anywhere because getting it registered for road use looked nigh on impossible. I'm told getting a Pop pick-up through the commercial vehicle SVA is a much more realistic proposition. It'd be nice to use the Sherpa bits just because they're already there, but it's not the end of the World if we can't make 'em fit.
I had a quick measure up at Loony's workshop today. The Sherpa axles are much wider than I thought. Not sure where I'd got my measurements from or whether I'd just made 'em up, but the original Pop front beam measures 47" between the hub faces. The Sherpa's a massive 62", so 7" wider each side. As I'm not going to run the original wings I don't have to worry about fitting the wheels inside them, which means I can go a little wider, but not that much.  
The Pop rear axle's 47" as well, while the Sherpa's 58".
Narrowing the Sherpa rear axle shouldn't be beyond us if we can do it with a Reliant one. You're right, the wheels need to sit close to the pick-up sides, which means we need to lose roughly the width of the tyres from either side of the axle.
Loony & I mused whether the Pop front beam would be up to the job. I know they're regularly used in drag racing but drag cars don't do a lot of cornering or heavy braking do they. Think I'll ring Pop Browns or Pop Parts Plus & see what they recommend.
I can't use the VW camper panels to mock up the pick-up bed now cos Loony's gone & welded 'em to a camper.  >:( Think I'll definitely go with a pair of those though. The ribbed camper van floor panel I liked turned out to be something like 120 quid, but Loony's parts catalogue shows a universal ribbed floor panel which would do the job for sensible money. Could use it for the cab floor too.    


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 05, 2008, 03:58:58 PM
Bobbi, the MSVA manual's a bit vague in all the places we need it to be specific- it says only that the examiner must check the brake lines for "unsuitable joint fittings". It doesn't say what they should or shouldn't be. There's also no mention of tyre age. A lot of the potential pitfalls I've heard of are just word of mouth. I need to speak to someone who can give me a definitive answer. ByzMax has put a couple of trikes through the test I believe, but I can't get hold of him.
I'll try Chris, the tester who posts on the 100% forum, during office hours on Monday.


Title: Re: Manky's Pop.
Post by: panthershaun on January 05, 2008, 11:15:14 PM
Didn't mean to throw water on the fire mate, just a concern thats all ;) Grizz thinks the Pop front end is man enough for what we want to do, that is good enough for me ;D ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 06, 2008, 09:56:32 PM
Shaun & Brock -is this Kev Rooney, the NSRA guy who's on the consultation committee of the SVA group?
I took this pic at Hayling Island last year.


Title: Re: Manky's Pop.
Post by: panthershaun on January 07, 2008, 08:32:53 PM
yup ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 07, 2008, 09:17:18 PM
Emailed him yet Shauny?
I called in at Valley Gas Speed Shop in Newbury, Berks this afternoon. I was dropping off some trike parts at the powder-coaters next door. Anyway, I wandered in to ask Jimmy's advice on axles. Nice guy. He happily spent the best part of an hour talking chassis, beams, engine mounts, axle ratios etc, with a complete novice, with no sale at the end of it. He reckons the Sherpa rear axle gearing will be fine. One of his customers is running a standard. original Pop front beam in conjunction with a big block Chevy motor with no problems at all. Then he gave me the number of a local guy who's selling a complete Pop front set up, including split wishbones, with disc brake conversion. A complete bolt-in unit. Only problem is he wants 300 quid for it. About twice what I'd want to pay, but then how much would I spend uprating my own bits?


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 08, 2008, 08:30:00 PM
I rang the chap with the disc braked Pop bits today. He lives about 15 miles from Basingstoke where I work. He's Jan Summerville, a drag racer of some repute, who's the guy with the big block Chevy engined car. The Pop set-up was in his race car -he's swapping it for a dropped tube axle, which is why it's for sale. Included in the price is a pair of "Centreline" style wheels & tyres, which I won't need, so I'm going to see him on Friday to take a look & haggle a price, (I'm cr*p at haggling  :().


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 08, 2008, 08:56:01 PM
I rang the DVLA this afternoon & spoke to the woman who sent me the "we want to inspect your vehicle" letter.
They're not happy that I'm "restoring" a vehicle which doesn't have a VIN number stamped on it's chassis & has lost it's body mounted VIN plate. I've got no way of proving to their satisfaction that the car I've got is actually the one the number plates came from. The Pop's now listed on their computer as a scrapped vehicle. Bugger.
So it's SVA time for the Pop. PantherShaun already knows Kev Rooney, who was on the consulting committee when the regs were drawn up & is a keen rodder himself. If anyone can guide me through the red tape he can. So I'm waiting for an introduction from Shaun & Kev's phone number.
I'm clinging to the hope that, as I've been told, commercial vehicle, (i.e pickup), SVA is far easier to pass than the car equivalent, due to the bus, coach, taxi & lorry companies lobbying far louder for exemptions than the custom & kit car boys did.
If the Pop's going to become a Q plated new vehicle then I may as well buy a 350 quid basic chassis package from Valley Gas Speed Shop & do the job properly. This is supposed to be a budget build & it's already creeping towards the total I wanted to spend, but with luck, at the end of it, I'll have a totally legit "new" car, which won't need MOTing for 3 years & will withstand any inspection of it's paperwork. 


Title: Re: Manky's Pop.
Post by: panthershaun on January 10, 2008, 09:16:07 PM
you been PM'd manky ;) ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 10, 2008, 10:01:10 PM
PM safely received Shaun. Many thanks. ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 12, 2008, 12:36:46 AM
Taz & I drove to Thatcham in Berkshire this evening to see a man about a Pop axle. I was given his phone number by Jimmy of Valley Gas Speed Shop. It was a standard Pop axle fitted with disc brakes.
No good for us unfortunately cos it had Centreline wheels fitted on spindle mounts -one large centre nut to hold the wheel on, rather than the usual circle of 4 or 5 nuts. The discs actually bolt to the back of the wheel instead of to the hub, so that when you take the wheel off the disc comes off with it. I want to use my taxi cab rims, so would have to make up some kind of adaptor to either mount my taxi wheels to his spindle mounts or his discs to my wheels. Either way it was more expense & work than it was worth, so we gave the axle a miss.
Worth the hour's drive to get there though cos the guy turned out to be Jan Summerville & his Pop's the red, big block powered one pictured on the cover of Custom Car a couple of months ago doing an amazing wheel stand off the line at the HotRod Drags at Avon Park. It wasn't wearing the Pop beam at the time, but a straight tube axle, which bent on landing, as did the front chassis legs. Jan's sorted them both now in time for another season's racing. Interestingly, his Pop's running a boxed standard Pop chassis. I got to have a sit in the driver's seat. Must be a scary thing to drive!   


Title: Re: Manky's Pop.
Post by: madron on January 13, 2008, 11:11:58 AM
ya mankiness i have a spare standard pop front axle yours for 10.00 thats what it cost me if you can collect (doncaster) or if not in a hurry could bring to billing    ron


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 13, 2008, 11:15:07 AM
I've still got my original one at the moment, but my brother Brock asked if I had a spare for his drag car. So yup, will take you up on the offer Sir. Thank you.


Title: Re: Manky's Pop.
Post by: panthershaun on January 13, 2008, 02:08:12 PM
and if you don't want it Manky I'll take it ;D ;D


Title: Re: Manky's Pop.
Post by: madron on January 13, 2008, 03:43:41 PM
ok mankey first if not panthershaun  pm to sort out   ron


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 13, 2008, 10:12:35 PM
I'll ask Brock to get in touch with you.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 10, 2008, 11:09:12 PM
We've decided to use the standard Pop front axle & steering set-up, but move the transverse spring from ahead of the beam to directly above it, to shorten the nose of the chassis & fit everything in behind the grille. I've borrowed a similar set-up from my mate Richard at Valley Gas Speed Shop so we can measure up for the new chassis more accurately. Picked it up this morning & Loony, PD & I spent the evening mocking up the Pop & working out dimensions. Taz was on coffee & Pot Noodle duty.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 10, 2008, 11:27:59 PM
6" of ground clearance under the cab will give us about 4" under the front grille. The frame needs to be Z'ed at either end to kick it up to clear the rear axle & meet the front spring. 20" off the deck at both ends.
PantherShaun's chatted to Kev the SVA guy & he reckons that to get the Pop through a commercial pick-up SVA, the pick-up bed needs to be longer than the interior of the cab. Apparently that's to discourage people from nailing a window box sized bed on the back of their rods to sneak through. This is maybe a little longer than I first planned, but it'll comply.
We'd assumed we'd need to narrow the Sherpa rear axle, but once we tried it in place, it looks spot on. Result. :)
Note the Reliant cylinder head propping up the rear panel!


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 10, 2008, 11:38:47 PM
We've pushed the front axle as far forward as we can to give more room to shoehorn the engine in. The inner wings have gone to give more room for that V8 -& also cos I just like the look. 


Title: Re: Manky's Pop.
Post by: panthershaun on February 11, 2008, 10:18:25 AM
thats looking bloody good mate, so how much wider does the Sherpa axle look compared to the pop front? I may try and source a Sherpa axle to fit mine than I can use the Taxi wheels and only get wheel adapters for the front.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on February 11, 2008, 10:21:58 AM
thats looking the bis :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 11, 2008, 12:04:50 PM
Thanks guys. Hoping to order up the new chassis tomorrow. Valley Gas are building a Gasser Pop at the moment so some of the basic measurements can be taken from the rails for that. The rest will be scribbled on a bit of paper by us -"build us a chassis round that lot please mister".
We weren't too concerned about axle width for the purposes of measuring for the chassis so didn't actually compare Sherpa to Pop, but it looked O.K, maybe just a couple of inches wider overall. Richard's Pop front axle's been fitted with adapted spring perches that relocate the spring directly over the beam. He had a new shorter bottom spring leaf made by a blacksmith for 12 quid. He's also fitted Morris Marina hubs so he can run disc brakes. I'd like to do something similar with mine. Only problem is, that gives you a 4 bolt stud pattern, rather than the Sherpa's 5, so you'd need adaptors, which would probably bring the front axle width out to match the rear.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on February 11, 2008, 01:22:50 PM
i thought sherpa's had disks on the front?


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 11, 2008, 03:06:02 PM
They do, but the Sherpa front axle's way wider than we want & is a very heavy cast beam. Doesn't look easy to narrow & has no means of fitting a transverse spring. I was going to try & use it cos I thought the Pop one would be too lightweight for a Rover powered car, but everyone I talk to says it'll be fine -loads of rod & drag car drivers use 'em.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on February 11, 2008, 03:38:46 PM
ar right then back to the plot


Title: Re: Manky's Pop.
Post by: brock on February 11, 2008, 07:45:08 PM
   just out of interest, have you pulled the Sherpa hub apart to check bearing sizes and spacing ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 11, 2008, 07:54:52 PM
Aha! Now there's an idea that hadn't occurred to me, (very few ideas do). I'm told there isn't a disc set up that'll bolt straight onto a Pop axle -they all require some degree of machine work. So using the Sherpa hub & retaining the same bolt pattern front & back would be a good thing.


Title: Re: Manky's Pop.
Post by: panthershaun on February 11, 2008, 08:35:54 PM
I'm told there isn't a disc set up that'll bolt straight onto a Pop axle -they all require some degree of machine work.
Not what I've been told Manky :o Triumph spitfire hubs are apparently a straight swap, all you need is a spacer turned up to locate the hub on the spindle and fit inside the oil seal :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 11, 2008, 08:57:11 PM
all you need is a spacer turned up to locate the hub on the spindle and fit inside the oil seal

-isn't that "some degree of machine work"?


Title: Re: Manky's Pop.
Post by: panthershaun on February 11, 2008, 10:49:55 PM
OK OK you win birthdayboy  ::) ::) :P :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 11, 2008, 11:27:52 PM
 ;) :P


Title: Re: Manky's Pop.
Post by: madron on February 12, 2008, 12:14:58 AM
triumph herald discs swap straight over using pop inner bearing and herald outer or using a small backing spacer viva go on or cortina mk3 will fit using a small stepped spacer behind and under the rear bearing if memory serves me but all will need a caliper mount fabricating   phew that was a lot of brain matter to remember as havnt done one for years


Title: Re: Manky's Pop.
Post by: brock on February 12, 2008, 12:41:49 AM
   pretty much what I thought, they all seem to need at least one spacer or stepped sleeve so might it make sense to keep the stud pattern common and look into using what you have, no idea if it will work just interested really 


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 12, 2008, 08:25:34 AM
Precisely. I've got a Sherpa axle sat outside Loony's workshop. I haven't got a set of Marina, Cortina or Herald hubs about my person. So it makes sense to recycle what I've got, if they're gonna need as much machining as anything else.


Title: Re: Manky's Pop.
Post by: panthershaun on February 12, 2008, 09:17:58 AM
check out this link, you may have already seen it but it is very helpful.

http://www.flatheadv8.freeserve.co.uk/martsframes.htm

 ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on February 12, 2008, 09:20:43 AM
the link doesn't take you straight in, after the home page, go to index and look at the bottom right hand list and you will see a picture of old rusty, under that is the link to Unfinished Pop, try page 6 on that link.

phew :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 12, 2008, 10:58:17 PM
Interesting.
Measured up the axles today. Richard's front Pop beam, with Marina hubs & 4 bolt wheels, (Wolsey maybe), is 53 inches wide from outside edge to outside edge of the tyres.
My Sherpa rear axle's 64 inches. The extra width looks right though cos the bodywork curves out from the front -the nose of a Pop's very narrow once you take the big flared arches off. The Sherpa front axle was definitely too wide though.
Today Taz, Lunatic & I drove over to Valley Gas Speed Shop in Newbury, Berks, clutching a scrap of paper with a few scribbled measurements. Amazingly, Jimmy actually seemed to think he could build us a chassis from that. Should be ready within the next two weeks.  ;D


Title: Re: Manky's Pop.
Post by: poprodder on February 17, 2008, 01:13:19 PM
hi,
easy way to mount axle under spring on a pop is to use model y spring perches.
gasser style!!!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 17, 2008, 03:28:28 PM
Great! Got any about your person?


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 20, 2008, 07:11:59 PM
PantherShaun called in at Loony's workshop yesterday & carted off my old original Pop chassis for his own pick-up project. So now I'm committed to new rolling gear. I'm chassisless until Valley Gas knock up the new box section rails for me.
Spent a few minutes at my lock-up in Basingstoke after work today & got the Rover motor fired up & running. Sounds awesome with the roar of the open Range Rover headers bouncing off the walls! Everyone should have a V8 sat in the garage -just to fire up when things aren't going so smoothly. Instant grin inducer.  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on February 20, 2008, 11:49:38 PM
I've got some of that on video from Tuesday ;D ;D ;D ;D can let you have it if you beg :P :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 21, 2008, 04:57:01 AM
Please, please, please!
Can't really post it here as video clips take up a hell of a lot of room on the site, but if you can host it elsewhere, (YouTube?), you can post the link to it here.


Title: Re: Manky's Pop.
Post by: panthershaun on February 21, 2008, 10:57:40 AM
here you go mate, hope this goes someway to appeasing my appalling behavior on another thread :-[ :-[

sorry about the commentary by the p1**head at the start >:(

http://uk.youtube.com/watch?v=z0RTqZDSuDU


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on February 21, 2008, 11:16:53 AM
oooo thats well nice :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 21, 2008, 06:37:40 PM
Fired it up again this afternoon. Burst into life with the first touch of the wires on the battery terminals & ticked over very nicely. Collect the new chassis from Valley Gas Speed Shop next week, bung the motor in & nail the body on & away we go -I wish. Definitely given my enthusiasm for the project a big boost though. Can't wait to start putting it together now.
My lock-up's usually very quiet, tranquil even. It's quite pleasant to tinker with the trike there on a Summer's afternoon. Although it's in a service yard behind a row of shops on a council estate, it's normally deserted. Not the day Shaun turned up though. Shaun, Loony & myself, plus a bunch of builders remodelling one of the shops, plus 2 guys from neighbouring garages, plus some drunk from the pub next door who thinks he's an expert on engines. The rumble of the Rover motor seemed to draw them all in. It's the drunk guy you can hear advising us to rev it more at the start of that clip. However you can also hear Loony telling me not to rev it too much cos the flames from the open exhausts were firing straight onto the plastic fuel can!
Safety at all times people.  :P


Title: Re: Manky's Pop.
Post by: brock on February 21, 2008, 07:19:01 PM
   my favorite bit is when you have battery, fuel can, jump leads etc all balanced on top of it and at the first touch of the throttle it falls over


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 21, 2008, 07:28:34 PM
Obviously only a fool would start an engine up without first ensuring it's properly secured.
Ahem. :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 23, 2008, 11:31:39 PM
Called in at Loony's workshop this afternoon. He's picked up a couple of sheets of 18/20 gauge steel to create the rest of the cab back with. Will take a lot of work to create the double curve of the corners, but should look good when it's done.
We arrived to find the cab laying on it's side. Had Loony been racing it round the yard & found it doesn't corner too well without wheels? Nope, he'd rolled it over to take a better look at the sills. It's a tribute to the bracing we put in at the start that the body could be upended like that & still stay in shape & intact. Unfortunately the bottom few inches of the shell are pretty rotten. The last 6 inches of the door skins are full of filler which has bubbled & lifted, & the A panels are in bad shape.
The curves aren't easy to replicate so it's time to buy in a couple of repair pieces. A pair of A panels, (the bit in front of the door, including the lower hinge mount. I think Shaun's already changed this bit on his own project), plus a pair of door repair sections, (the bottom 6 inches).
Loony's decided to ditch the original sills as well & make up new, more slimline ones. I can't wait to just be able to open the door & sit inside the shell. :) 


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 23, 2008, 11:33:32 PM
.


Title: Re: Manky's Pop.
Post by: panthershaun on February 24, 2008, 07:09:39 PM
I think Shaun's already changed this bit on his own project)

Only on the drivers side, Grizz made up his own repair section ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 07, 2008, 11:52:55 PM
No real progress to report yet. I ordered a pile of bits from "Pop Parts Plus" & collected them from their stall at the NSRA swapmeet in Essex at the weekend. I've now got all the window window mechanisms & door latches, as well as a pair of A post repair sections & the repair panel for the passenger door. They're re-tooling at the moment & won't be able to supply the driver's door panel for a week or so. I also picked up a pair of repro '32 Ford exterior door handles.
Loony's got a couple of other customer's cars to work on but hopefully the Pop bodyshell will be a lot more solid by the time Valley Gas Speed Shop get the new chassis sorted.
I had a quick chat to Kev of the SVA consultation committee at the swapmeet. He reckons if I can find proof of the Rover engine's age I only have to conform to the emmisions regs for that year, which will be a bonus.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 07, 2008, 11:54:48 PM
.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on March 08, 2008, 12:24:07 PM
them pre molding bits look dead handy :) is that lunatics bsa? luv the helmet :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 08, 2008, 02:08:32 PM
The German helmet makes the piercing in his nose look like a Hitler moustache!
Yup, that's the Beezer. A little Bantam. Not sure what size but it don't matter cos it's buggered.
He & PD can't decide what to do with it. PD's also got a modern trailie which they blat up & down the yard on -hence the helmet.
The bottoms of my Pop doors consist almost entirely of filler & fibreglass so the repair panels will give us 6 inches of fresh steel in there.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2008, 10:26:08 PM
Woo hoo! My new chassis' almost done!
I know it doesn't look much but this is the skeleton on which the whole car will hang, so it's a pretty big deal really. We haven't got the facilities, or the floor space, to build this ourselves & get it totally flat & square. Cost 500 quid, which everyone tells me is a good price. I'm happy.
This is the back end.


Title: Re: Manky's Pop.
Post by: BikerGran on March 12, 2008, 10:31:39 PM
Very impressive!

What's the reason for one side being longer than the other?


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2008, 10:37:38 PM
The ends of the frame legs need cutting off to length & there's a spring perch to be added to the front & that's about it. The rest is down to us.
The engine will sit between the front kicked up rails, with the mounts bolted to the inside edge of the rail, rather than sitting on top of it.
The front kick up will start just inside the footwell of the cab & the back will do the same so that the rear rails come out about halfway up the back of the cab body.
There's a 12 inch kick up at the rear of the chassis & a bit less at the front, meaning the body should sit about 6 inches off the deck. This isn't the full width of the car. The chassis runs straight down the centre of the vehicle, tapering out slightly towards the back -we'll weld on outriggers to bolt the outer edges of the bodywork to. Tomorrow I'm heading back to Valley Gas Speed Shop to pay the bill, then one of their employees, Richard, who lives in Basingstoke, will deliver it for me on his way home from work in his Transit van.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2008, 10:44:47 PM
Valley Gas is run by Jimmy & his good lady Elle. They're building her a replica '27 track T, (a fibreglass bodied 2 seater roadster). The chassis rails are built from channel that's been specially laser cut with Maltese crosses down it's entire length.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2008, 10:48:00 PM
Lovely looking mark 4 Zephyr starting to take shape in the workshop. The guys are rushing to get 2 customers' cars ready for WheelsDay in 2 week's time.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2008, 10:50:09 PM
I'll have one of these please. Don't bother wrapping it, I'll take it with me now. ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2008, 10:52:44 PM
Another Dodge Charger. Common as muck ain't they!  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2008, 10:55:04 PM
.


Title: Re: Manky's Pop.
Post by: panthershaun on March 12, 2008, 10:58:15 PM
meaning the body should sit about 6 inches off the deck.
And I thought you were going low ::) ::) :-*


Title: Re: Manky's Pop.
Post by: tazet on March 12, 2008, 11:01:37 PM
Well we all know what a blokes 6 inches is compared to a womans  :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2008, 09:07:11 PM
Right. The shiny new chassis was safely delivered to Lunatic's secret country lair, free of charge, thanks to Richard of Valley Gas & his trusty rusty Tranny van. Thanks mate. Unfortunately Loony's workshop was full so it had to sit out in the rain. I'll slap a temporary coat of red oxide on it all to keep the rust bugs at bay -it'll be shot-blasted off before the final powder-coat's applied.
So we had a bit of a measure up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2008, 09:24:59 PM
Richard just happens to have a Pop front axle that's been converted from having the spring mounted across the front of the beam, to being mounted directly over it. That shortens the front of the chassis set-up & means we can shoe-horn it all inside the original Pop body panels.
So we nicked it for a while.
When we came up with the chassis dimensions a lot of it was guesswork -we won't really know what we need till we start putting things together. The ride height's supposed to be around 6 inches to the underside of the rails but here it sits at more like 10.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2008, 09:31:14 PM
Valley Gas tack-welded a spring perch on the front cross member for us, but we suspected it'd need moving so it wasn't fully welded. We weren't sure how much the spring would compress with the weight of a V8 Rover motor on it. No problem. Lunatic's got one of his own sat in the corner of the workshop.
So we nicked it for a while.
Maybe the mounts need a little work.  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2008, 09:33:28 PM
Didn't make as much difference as we'd thought. The ride height dropped by around an inch. O.K, we'll lift the spring mount then, which'll drop the chassis. Sorted. Jimmy at Valley Gas set the perch at around 4 degrees, which is necessary for proper suspension movement. We're thinking maybe cut the cross member & Z it -lift it by the depth of the tube, so the bottom edge is level with the top edge of the chassis, then fill in the sides with angled tube pieces. Does that make sense? Anyway, that'll raise the spring mount by 80mm, (just over 3 inches), & drop the chassis by the same amount. Using a spring with the mounting eyes curling upwards instead of downwards, ("reversed eye"), will add another inch & bring us down to the 6 inch ride height we're after.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2008, 09:59:58 PM
Onto the back end then.
We're using a Sherpa axle, a favourite with rod & race car builders. They're strong enough to take the 3 & a 1/2 litre Rover power & come in several ratios. Sherpa actually fitted some of their vans with Rover V8 motors. The back end's easier to drop. Suspension will be courtesy of a pair of coil over shocks, mounted from a cross member above the axle, with sideways & fore & aft movement controlled by triangulated 4 bar linkages. One of the simplest systems to build & set up properly.
The finished wheelbase will be 115 inches.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2008, 10:17:57 PM
We scribbled a shopping list & trundled back to Valley Gas Speed Shop.
Jimmy & the guys, (& the lovely Elle of course), are genuinely helpful & happy to sit with a pair of ammateurs like Loony & I, (we're first time hotrod builders), & go through the various options with us.
We came home with the box section tubing for the rear shock mounting cross member, as well as the gearbox mounting cross member, as well as a big pile of assorted ready-made brackets. At about 3 quid each, simple tab mounts are hardly worth the trouble of making ourselves. Jimmy even threw in a pair of 4 bar mounts they'd just cut off a new model A chassis for free. Top chap.
We also ordered a complete new front leaf spring after we found one in his suppliers catalogue of exactly the size we needed. 50 quid. Also on the list was a pair of new spring shackles, bushes & mounting bolts. Should be here in a week or so.


Title: Re: Manky's Pop.
Post by: lunatic on March 20, 2008, 08:38:08 PM
Mr Manky came over this afternoon and cut all the lugs off the sherpa back axle, then ground them flush. Thats it really!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on March 20, 2008, 09:43:28 PM
sorta sat down on the job again then :)


Title: Re: Manky's Pop.
Post by: panthershaun on March 21, 2008, 08:19:04 PM
Hotrod's Hotrod's I chuffing love Hotrod's  ;D ;D ;D forget the trike mankey lets have a race to build a modified ;D ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on March 21, 2008, 08:45:05 PM
Richard just happens to have a Pop front axle that's been converted from having the spring mounted across the front of the beam, to being mounted directly over it.

Got to ask, what wheels are they on the front mate?? ??? :P :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 21, 2008, 09:30:02 PM
Not sure -Wolsley maybe. I'll check with Richard. Marina hubs.
I've got 2 trikes & a Pop to build & getting nowhere with any of 'em! You think I need another project! :P


Title: Re: Manky's Pop.
Post by: BikerGran on March 21, 2008, 10:56:11 PM
They say it's better to travel hopefully than to arrive................


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 01, 2008, 10:24:38 PM
Loony & I took another trip to Valley Gas Speed Shop in Newbury, Berks this afternoon & picked up the components for the Pop suspension. No I'm not going to tell you how much this lot cost. A very small box of bits with a very large price tag. Loony & I bet each other how much it'd cost on the way there. Unfortunately I won.
The original, very optimistic budget for this build was around the thousand quid mark for a motor built on the original chassis with Ford Consul power. That's now been upgraded to about 3 grand for basically a brand new car, on a new tailor made chassis, with V8 Rover power. To put it in prospective, that's still half the cost of my second hand Fiesta.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 01, 2008, 10:26:34 PM
Brand new front transverse leaf spring with reversed mounting eyes, new spring shackles & hangers, with new bottom shock absorber mounts.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 01, 2008, 10:31:41 PM
Lovely shiny new Gaz adjustable coil-over shocks with 160 pound springs. Plus enough tube for the triangulated 4 bar linkage with threaded weld-in bosses & rose joints & spacers for front & rear linkages.
A complete suspension set-up.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on April 02, 2008, 12:01:31 AM
Nice


Title: Re: Manky's Pop.
Post by: panthershaun on April 02, 2008, 05:27:46 AM
very, very nice ;D ;D do those new spring mounts put the spring over the axle then Manky??


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2008, 09:27:00 AM
Yeah. We borrowed a similar set-up from Richard, one of the Valley Gas guys, to measure up for the chassis. It brings the front spring back by 3 or 4 inches & means we can keep everything tucked inside the original Pop bodywork, even though we're running the V8 instead of the little Ford sidevalve. The other option would've been to mount the spring perch through the front of the radiator grille as a lot of the American rat rods do, but I didn't want to break the line of that long Pop nose cos I think that's it's defining shape -one of the features that make it instantly recognisable as a Pop.


Title: Re: Manky's Pop.
Post by: brock on April 02, 2008, 07:16:38 PM
To put it in prospective, that's still half the cost of my second hand Fiesta.

    prospective ?

         ???

          ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2008, 08:43:30 PM
Did I write that?! Shame on me. PERspective.

Spent the afternoon at Lunatic's workshop today, measuring things, trying ideas & generally buggering about. We decided the ride height was still too high, so we had to raise the front spring mount in order to lower the body. Easiest way was to attack my new 500 quid chassis with a grinder & cut out the front cross member, (having first braced the rails with a length of old angle iron). The cut section was then raised by an inch & a half & tacked back in. We'll add triangular gussets either side of it once we know it's in the right place. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2008, 08:45:55 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2008, 08:47:35 PM
Yes, we know the axle's in back to front here but the ride height's the same which is all we were worried about.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2008, 08:50:57 PM
The masking tape under the centre of the chassis is the finished height of the sills. About 6 inches off the road, which is what we were after. Mind you, it'll be less with two people & a V8 motor in it. Hope we've got it right!


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2008, 08:51:47 PM
The rad shell will be a couple of inches higher than this but you get the general idea.


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 02, 2008, 09:26:47 PM
Nice!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on April 02, 2008, 09:32:30 PM
bloody brill ;D


Title: Re: Manky's Pop.
Post by: panthershaun on April 02, 2008, 09:45:02 PM
like the stance ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2008, 09:54:56 PM
Loony's or the car's? :)
I'm hoping I can liberate the Austin Chummy seat frames I sold to Loony last year. You can see one in red oxide inside the Pop bodyshell in that pic. They'll make cool bomber style seats. The top of the chassis rails will be the floor level of the cab. The prop shaft tunnel should end up about 5 inches tall between the seats. There's actually a lot more room in the cab than we first thought.  ;D


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on April 02, 2008, 11:02:19 PM
U  mean u can turn your Head both ways  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 02, 2008, 11:07:51 PM
Yup. Should even be able to turn the steering wheel without opening the window first!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on April 02, 2008, 11:18:33 PM
;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 03, 2008, 06:38:56 PM
Another quick measure up today & we reckon the top of the carbs should be just about level with the bottom of the windscreen, so maybe just poking through the bonnet. If that's the case I might swap the twin SUs for a 4 barrel Holley & do the job properly with 4 velocity stacks up in front of the screen.
I've had a week off work &, as usual, achieved bugger all. I've got an hour's commute between home & Marcus' workshop, (only takes 45 minutes when I'm going to work at 5 in the morning). By the time I've done a few odds & ends at home & got organised enough to get going, it's lunchtime before I get there. Had to nip over to Valley Gas for some more box section today to make an extra cross member behind the cab & some gussets for the front cross member. That was another couple of hours gone.
Some more measuring & we able to add the first mounting tabs to the back axle. These will take the rose jointed bottom rods of the 4 bar linkage. They'll run parallel to the ground & connect to the chassis at the bottom of the rear kick up. Ideally the propshaft should run up to the axle by between 2 & 4 degrees for unhindered suspension movement, hence the magnetic angle finder on the diff.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 04, 2008, 09:20:54 PM
Called in at Loony's workshop again this afternoon. Another day of running to & fro, so not much time, but enough to cut out some gussets to strengthen the reworked front cross member. Then Loony glued 'em in place.


Title: Re: Manky's Pop.
Post by: texon on April 07, 2008, 05:54:30 PM
And a fine job they n you did it looks well m8 but better get a move on or they will change the laws again to stop rods being on their pristine roads


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 07, 2008, 06:21:45 PM
Yeah I know. New SVA regs due next year -European harmony & all that. So I've got to get this sorted & on the road this year. Two trikes & a pick-up to get built & registered. No more projects!


Title: Re: Manky's Pop.
Post by: panthershaun on April 07, 2008, 07:20:39 PM
No more projects!

Yeah :o righto mate ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 07, 2008, 07:29:28 PM
Well, no more for this year anyway.

.....maybe. :P

Seriously, if I couldn't get the Pop registered for some reason, I'd still push on & build it & just take it drag racing instead. The latest round of SVA/TUV/MOT stuff sounds pretty scary but I prefer to live in hope, (maybe it's blind optimism, I dunno). The modified car & bike market's worth a fortune in this country -not just the custom crowd but the hothatch boys, the dayglo sports bike riders, the restoration chaps & everyone else. Lots of peers of the Realm pootling round the countryside in vintage motors & performance car owners with lots of cash & therefore lots of clout. Would they really let Parliament kill off the whole scene?
Yeah, they probably would, but I'm hoping there'll still be loopholes & clauses we can exploit.
Lots more things I want to build yet!


Title: Re: Manky's Pop.
Post by: panthershaun on April 08, 2008, 08:21:30 AM
I know what you mean  :-\ but we have to live in hope  ;D and as you say most of the most powerful people in the country and no I don't mean the Queen or that muppet the PM drive around in Vintage cars or campaign some serious vintage specials so they may push to keep our life style alive :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 08, 2008, 10:46:23 PM
Loony & I stripped down my Pop front axle today. Scraped off 55 years of gunge & thought about how we're going to mount it on the new chassis.
It'll hang on the new transverse spring in the same way the original did & be located by a radius rod on either side. The original used a short wishbone set-up. We've cut the cast ends off, that attach to the front beam, & will create extended arms using the rear ones. They'll end in rose joints attached to the chassis near the bulkhead.


Title: Re: Manky's Pop.
Post by: madron on April 09, 2008, 07:19:37 PM
you could try welding  a vertical U section on the end of the small bit you chopped off drilled for top and bottom bushes or rose joints and then fitting a four bar setup with a transverse bar from frame to axle for stability and if not using the front and or rear oval tubes can i have them to make some old school springer forks pretty please


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 09, 2008, 09:59:01 PM
 :)
We like the old school radius arm set-up Ron, & the idea of recycling parts of the original car -especially because it doesn't cost anything! You're welcome to the shorter original wishbone oval tubes but I guess they're too short? Not sure if Shaun's using his rear ones or not.


Title: Re: Manky's Pop.
Post by: madron on April 09, 2008, 11:32:54 PM
the short ones i can use for short (bobber) springers and if shaun has a pair of rears i can make a pair for my chop can collect em when shabby comes down for body panels


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 10, 2008, 03:55:16 AM
No problem. We'll try not to weld them to anything then.  :)


Title: Re: Manky's Pop.
Post by: poprodder on April 11, 2008, 05:57:34 PM
are these any help.

(http://www.dropshots.com/photos/64941/20041128/135446.jpg)

(http://www.dropshots.com/photos/64941/20051203/160100.jpg)


Title: Re: Manky's Pop.
Post by: panthershaun on April 11, 2008, 07:08:35 PM
Are they up for crabs Chris? maybe we can do a deal ;)

Madron, I'm afraid I'm hanging on to all my bits at the moment until the beast is built, then some of the bits may be up for grabs but I do see a modified on the horizon ::) ::) ;D


Title: Re: Manky's Pop.
Post by: tazet on April 11, 2008, 09:10:27 PM
Hey! Poacher! Think Manky gets first dibs on it as it's in his thread  :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 11, 2008, 10:57:39 PM
S'O.K Hon. We've got all the parts to build our own set up. Just a couple of questions Chris:
Why are your modified radius arms angled inwards? Your chassis looks narrower than mine, (we're planning on sitting the Rover motor down lower between the rails than yours).
Are you using the standard Pop spring? We've bought a new replacement from Speedway, 26 inches wide with reversed eyes, which we'll hang on new spring mounts from the original holes on the Pop beam. So the spring will sit diectly over the axle.
Are you trimming the back edge off the spring perch, where it overhangs the back of the front cross member?
How long are your radius arms & where do they attach to the chassis?
What steering box are you using & where does it mount in relation to the ends of the radius arms?
What hubs are you running on that beam?


Title: Re: Manky's Pop.
Post by: madron on April 12, 2008, 12:06:37 AM
 i only ask as i have an idea to build oval rear leg springers so i will wait till you have finished your builds and all i ask is you keep me in mind if you have anything left if you trade for other things thats what its all about but if left over rather me than the scrap man gets em lol


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 12, 2008, 12:21:02 AM
Brock's just told me the angled radius arms are to allow extra clearance for the wheels on full lock -maybe we should be checking that!
Also the overhang on the spring perch may have a strengthening gusset underneath it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2008, 10:13:48 PM
Haven't updated you for a while.
Loony & I have been working on the rear suspension. We've gone for the simplest set up we can, namely a triangulated 4 bar with coil over shocks. I bought a bunch of universal mounting tabs, some suitable tube & a handful of rose joints when we picked up the chassis from Valley Gas Speed Shop. We've used those to make a pair of bottom locating bars, attached to the underside of the axle & running parallel to the chassis to mounting bosses welded into the chassis at the base of the rear kick up. Those set the position of the axle along the chassis.
Then we added another pair either side of the top of the diff housing & spreading out to meet the chassis at the top of the rear kick up. These stop the axle from moving sideways.
Neither of us have done this sort of thing before, so we were a bit worried the whole thing would bind or lock up solid under suspension travel. Lifting the chassis off the axle stands & lifting & lowering it proved our worries were unfounded -success!


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2008, 10:16:29 PM
We used offcuts of box section from the chassis to form some tidy top mounts.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2008, 10:25:41 PM
Each bar consists of a length of tube with threaded bosses welded into each end. A right handed thread on one end & a left handed one on the other. That'll let us fine tune the dimensions of the linkages on the final build.
Next job is to mount the shocks themselves -160 pound adjustable Gaz coil overs. The plan is to set the top eye of the shocks up into the box section cross member above the axle.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2008, 10:27:59 PM
.


Title: Re: Manky's Pop.
Post by: texon on April 19, 2008, 11:16:17 PM
that looks good not long now lol


Title: Re: Manky's Pop.
Post by: shabby on April 21, 2008, 05:57:31 PM
looking good there manky  ;D


Title: Re: Manky's Pop.
Post by: tazet on April 22, 2008, 07:46:02 PM
Some photos that were taken today.


Title: Re: Manky's Pop.
Post by: tazet on April 22, 2008, 07:46:35 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 22, 2008, 08:29:40 PM
The pics show our mate Richard's modified Pop front axle on my new spring. No hubs on my own Pop axle yet so Rich's is being used so we can get the chassis up on 4 wheels when needed.
Had a visit from Shabby & madron today -very nice to see you guys - especially as Ron brought along a pair of Vauxhall Viva hubs for me. Thanks matey.
They're Viva HC hubs, (the red bits in the photos). At the moment they've got adaptors to take VW wheels, which we might re-adapt to take the taxi cab wheels. Viva HAs are transverse spring with drum brakes, HBs are independant with drums & HCs are independant with discs I think.
All I need to do is find bearings with an outside diameter to fit the Viva hubs & an inside diameter to fit the Pop spindles. I'll buy a pair of new Viva discs from the local autofactors, but then need to find some suitable calipers.
I've played with the rear cross member & cut out a section either side for the coil over shocks to fit up into. I've also marked out a curved area that needs to be cut out to clear the diff on full suspension travel.


Title: Re: Manky's Pop.
Post by: shabby on April 22, 2008, 10:08:24 PM
not be long now manky,looks great. many many thanks for pop bits and all, will all get used well ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 22, 2008, 10:21:25 PM
Thanks for clearing our scrap valuable automobile parts.  ;D
Nice to put another face to a forum member. Top chaps, both of you.
Y'all come back real soon now y'hear.


Title: Re: Manky's Pop.
Post by: shabby on April 22, 2008, 10:35:16 PM
that we will, was a great day  ::)


Title: Re: Manky's Pop.
Post by: texon on April 22, 2008, 10:46:10 PM
they will be down again soon now they know the sizes of bolt you used to hold stuff down lol  ;D just phoned Ron he`s knackered and going to bed lol he`s getting to old for all this traveling lol  ;D


Title: Re: Manky's Pop.
Post by: tazet on April 22, 2008, 10:55:35 PM
Ah but Texon we have already changed the size of the bolts  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on April 23, 2008, 08:40:09 AM
coming along nicely guy's, have you got a side on photo of the rolling chassis??


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 23, 2008, 04:50:32 PM
I'll take one tomorrow Shaun. Difficult as there's always cars in front of the workshop door, getting in the way of the shot.


Title: Re: Manky's Pop.
Post by: shabby on April 24, 2008, 08:23:48 AM
Ah but Texon we have already changed the size of the bolts  ;D


but we posh ; got a socket set lol  ;D :D ;D


Title: Re: Manky's Pop.
Post by: texon on April 24, 2008, 04:42:48 PM
yes WE got a socket set we bought it between us  8)


Title: Re: Manky's Pop.
Post by: tazet on April 24, 2008, 06:02:22 PM
 ;D Ah but we've used car locking ones  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 24, 2008, 06:20:22 PM
Sorry Shaun, couldn't get a full side shot of the Pop chassis today -some muppet had parked a beat up ol' Consul in the way.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 24, 2008, 06:49:59 PM
I don't even own this many pairs of Molegrips.
No less than 9 pairs holding the three sections of Postie Dave's new sill together on the Consul.
Should be finished & on our pitch at the Basingstoke show in a couple of weeks time. Hope they get it sorted cos Dave's got to drive it home to Aldershot this evening!


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 24, 2008, 09:03:35 PM
Lunatic's cut out the curved section under the axle cross member for me & cleaned up the top shock mounts. This is how the shocks fit. Next job is to sort out the bottom mounts.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 24, 2008, 09:15:51 PM
We'll weld the long bracket with the holes in to the underside of the axle, then bolt the L shaped ones either side of it. They need some reshaping to line up with the bottom of the shocks but will form adjustable mounts. The shocks themselves are also adjustable for ride height & rebound, so we should be able to tweak it all until it's just right.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on April 25, 2008, 07:00:17 AM
thats moving along at a fine speed m8 bet yer glad Loony and PD are at hand :)


Title: Re: Manky's Pop.
Post by: Dave_postie on April 25, 2008, 07:44:31 AM
muppet, beat up old consul, oh dear, if any bits get moved on your pop" it was nt me. ;D and fancy leaving doughnuts in the fridge, next time you go madron + shabby check the fridge. ;D


Title: Re: Manky's Pop.
Post by: madron on April 25, 2008, 01:50:27 PM
muppet, beat up old consul, oh dear, if any bits get moved on your pop" it was nt me. ;D and fancy leaving doughnuts in the fridge, next time you go madron + shabby check the fridge. ;D
WE DID but thought we would leave some for later ron


Title: Re: Manky's Pop.
Post by: madron on April 25, 2008, 01:51:11 PM
yes WE got a socket set we bought it between us  8)
BOUGHT  you never buy only BORROW  for ever


Title: Re: Manky's Pop.
Post by: Mr_G on April 25, 2008, 04:16:18 PM
Liking it so far, keep us posted.  :)


Title: Re: Manky's Pop.
Post by: madron on April 25, 2008, 06:12:58 PM
chassis lookin well cant wait to see body on so get a visual how low its gonna be


Title: Re: Manky's Pop.
Post by: texon on April 25, 2008, 07:44:18 PM
I agree with you Ron cant wait but HOW LOW CAN YOU GO looking great Manky 8)


Title: Re: Manky's Pop.
Post by: madron on April 25, 2008, 09:23:13 PM
I agree with you Ron cant wait but HOW LOW CAN YOU GO looking great Manky 8)
you saw the slug (austin a55 lowrider) used to take cats eyes out if i touched brakes on em lol


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 25, 2008, 09:53:46 PM
6 inches of ground clearance for mine. I work in Basingstoke -land of the roundabout & speed bump, & you've already seen how bumpy the bottom of our garden is, where the Pop will live when it's done. Gotta be reasonably sensible! Well, as sensible as a V8 engined, roof-chopped pick-up truck can be anyway.
Spent a couple of hours in Loonyville today, welding in a fill-in piece under the axle cross member & making it all pretty. It'll never get seen but hey, I'll know it's there.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 25, 2008, 09:57:37 PM
The shocks sit at the recommended 25 degrees. Next job is to sort the bottom mounts out. Had a text this evening from Loony to say he'd come up with a very simple set up for that. We'll have a look when I go back tomorrow.


Title: Re: Manky's Pop.
Post by: brock on April 25, 2008, 10:12:28 PM
   what a coincidence, I also store old rags and thinners under the fab. bench


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 25, 2008, 10:54:37 PM
 ;D
Don't do this at home kids. It was body filler hardener, so marginally less flamable than thinners.


Title: Re: Manky's Pop.
Post by: shabby on April 26, 2008, 02:31:16 PM
muppet, beat up old consul, oh dear, if any bits get moved on your pop" it was nt me. ;D and fancy leaving doughnuts in the fridge, next time you go madron + shabby check the fridge. ;D
fridge fridge was it bolted down lol


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2008, 06:19:11 PM
Back at t'workshop after work today.
Loony's shock mount idea will work. A machined block bolted to a vertical plate welded to the axle. Adjustable by moving it up & down a series of holes in the welded plate. The front of the block tapped to take a half inch bolt. The bottom eye of the shock will sit on the unthreaded shank of the bolt. A fairly standard way of mounting shocks on rods I think, but one which hadn't occurred to us. So I need to get the mounting blocks machined up, preferably in stainless, as soon as poss. FLC, are you about?


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2008, 06:27:49 PM
We've only got 2 weeks to make this look vaguely like a car to show at the Basingstoke Transport Festival. Half the stuff we're showing will be unfinished projects so doesn't really matter how far we get, as long as it's recognisable as a Pop truck. As we've found at the Shepton Mallet bike show, the punters seem to like seeing "works in progress" as well as finished shiny vehicles.
So we thought we'd better bung the body on & just temporarily tack weld it to the chassis for now, (don't want it toppling off onto some passing child or something). Gave us a chance to see how it sits on the new chassis too.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2008, 06:39:57 PM
Loony practising his cool cruising stance.
"You wanna race punk? Thunder Road, outskirts of town, 10 minutes".
Trouble is the cab's full of a spidersweb of bracing poles at the moment, so it took 5 minutes of contorting to climb in. Once in though, it's suprisingly roomy. A comfortable amount of head & legroom & Loony's taller than me.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2008, 06:46:55 PM
8 inches of clearance under the doors at the moment, but that'll go down to about 6 by the time we've welded the sills on, which is what we originally planned for. The cab's sat on a bracing bar at the back & the firewall at the front so is about 3 inches too far forward. The rear chassis kick up will be hidden inside the cab, behind the seats, so the pick-up bed rails will exit the cab at the higher level.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2008, 06:52:48 PM
The Rover V8 motor's roughly 30 inches long from front to back, with another 27 for the auto gearbox. If all goes according to plan, it should sit perectly between the front chassis cross member & the firewall. The gearchange position should be the same as a normal car with a tunnel about 5 inches tall between the seats.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2008, 07:01:15 PM
Oh, the bike's a little CJ250 Honda, circa 1978, by the way.
PD's nephew's due to be joining the crew for a couple of week's work experience soon. They plan to give him the 50 quid bike as a project, to do as he wants with, under their guidance. There's talk of a bobber project. Cooler than spending your work experience time serving burgers in McDonalds.


Title: Re: Manky's Pop.
Post by: texon on April 26, 2008, 08:09:56 PM
Now that looks great m8 it gets the juices flowing I am going to be starting my pop pickup soon I hope when the council pull their finger out and get some work done I have sent you a pic of how I want to build it Manky because I still cant get owt to load up  ::)


Title: Re: Manky's Pop.
Post by: panthershaun on April 26, 2008, 09:58:37 PM
 :P :P :P :P :P :P :P :P :P :P looking good mate  :-* :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2008, 10:19:15 PM
Thank you gentlemen.  ;)
Tex, here's your drawing -very good. We'll add it to the "Ideas Sketchbook" part of the Motors section if that's O.K. Looking forward to seeing that one in the flesh!

Shaun, Madron left a wheel hub with us when he visited with Shabby the other day. Give us a shout when you get back from your hols & we'll nip it over to you.
Any progress on your Pop?


Title: Re: Manky's Pop.
Post by: flc on April 27, 2008, 08:36:32 AM
looking good andy, its getting me into doing my minor, give us a pm about machining. :)
cj looks nice i had a cb 250 g5 chop when i was a lad good times :)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on April 27, 2008, 10:35:03 AM
thats looking almost finished ;D Brock's got the same mounting idea on his axle aint he? looks good Manky and it works :) luv the stance of it oh the joys of aving a garage :) ...nice touch that Loony and PD have given the kid summut to develop..he's a lucky kid :)


Title: Re: Manky's Pop.
Post by: shabby on April 27, 2008, 10:53:46 AM
nice one texon ,will look sweeeeeeeeet  ;D


Title: Re: Manky's Pop.
Post by: texon on April 28, 2008, 08:49:30 PM
Well I got the pic now all i need do is build it I am collecting parts as I type any donations greatfilly received lol I got your old pop seat Manky and a fine patina they are too  ;D if you want to put the pic on the ideas sketchbook no prob I will send you some more I have one I did of a std pop so ppl can have a mess about with it for ideas also I have just drawn one of Ron's Jam Roller but you will have to ask Ron to use that you know what he`s like check avatar MY PRECIOUS  ;D  ;D  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 28, 2008, 09:12:12 PM
Has Ron been spreading my old Pop parts all over Yorkshire?! You're very welcome mate.  ;)
The more input we get the better so feel free to email us any more artwork you've got.

VB, let's hope it encourages the lad to do something positive -most of the kids I see in Basingstoke can't be bothered to do anything. Start 'em young eh. The boys had a visit from the Health & Safety people to check the premises were trainee-friendly, so much feverish tidying up ensued. Passed with flying colours though.
Brock's been in touch via email to suggest a better way of mounting the shock absorbers. A length of box section, (same as the chassis if we've got enough left), with one face cut off & welded vertically to the axle. A series of holes in the front face for shock mount adjustment, then simply bolt through the eye of the shock into a nut & spring washer behind the box. Very simple but much stronger than flat plate.


3 hole shock mounts (http://www.tperformance.com/street_rod_store/3100/rear_axle_lower_shock-mounting_kits/)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on April 28, 2008, 09:34:06 PM
VB, let's hope it encourages the lad to do something positive -most of the kids I see in Basingstoke can't be bothered to do anything. Start 'em young eh. The boys had a visit from the Health & Safety people to check the premises were trainee-friendly, so much feverish tidying up ensued. Passed with flying colours though.
Brock's been in touch via email to suggest a better way of mounting the shock absorbers. A length of box section, (same as the chassis if we've got enough left), with one face cut off & welded vertically to the axle. A series of holes in the front face for shock mount adjustment, then simply bolt through the eye of the shock into a nut & spring washer behind the box. Very simple but much stronger than flat plate.


3 hole shock mounts (http://www.tperformance.com/street_rod_store/3100/rear_axle_lower_shock-mounting_kits/)


Now thats a good idea maybe with a bit of thought that could be applied to da trikes back end frame mounting cos it would still be removable


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 28, 2008, 10:08:15 PM
Had some errands to do after work today, but managed to cut another cross member to sit behind the cab. Loony's tacked it in place. Not to strengthen the chassis -the thing's built like a tank already -just to give somewhere to bolt the front of the pick-up bed to, as well as the original oval Ford fuel tank, which'll sit in the bed, tucked up against the back of the cab. 
I started cutting out the new design shock mounts, but ran out of time, so will take some piccies tomorrow.


Title: Re: Manky's Pop.
Post by: shabby on April 28, 2008, 11:28:29 PM
looks really well there manky need to get my finger out too lol ;D


Title: Re: Manky's Pop.
Post by: madron on April 29, 2008, 07:39:48 PM
Well I got the pic now all i need do is build it I am collecting parts as I type any donations greatfilly received lol I got your old pop seat Manky and a fine patina they are too  ;D if you want to put the pic on the ideas sketchbook no prob I will send you some more I have one I did of a std pop so ppl can have a mess about with it for ideas also I have just drawn one of Ron's Jam Roller but you will have to ask Ron to use that you know what he`s like check avatar MY PRECIOUS  ;D  ;D  ;D

manky you have my permission to print anything texon draws EXCEPT ME  lol


Title: Re: Manky's Pop.
Post by: texon on April 30, 2008, 07:35:08 AM
uuuugggghh the thought of it  :-[ Manky did you get the other pics I emailed you


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 08:18:11 AM
Yup, got the drawings thanks mate. We'll get them online soon -well, Taz will. I'm slowly getting to grips with this techno stuff, but I'm still not confident to do stuff without her being there in case I bugger it up. She's just left for her first carriage driving event of the year & won't be back till Sunday.
For those who don't know, Taz & I live in a cottage on a country estate that comes with her job. She's head groom/stable manager/general dogsbody for Lord Onslow of Surrey. A big part of the job involves looking after & training his carriage driving ponies -Welsh Palominos. They compete in driving events all over the country & she's loading up the horsebox as we speak to head off to Brighton for the first event of the year.  


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 09:52:25 AM
My day off today, so when I get a minute I'll sand the welds smooth on the shock mounts & drill the holes. We were going to add a series of holes for adjustment, but we'll be putting the shocks on the lowest setting & any adjustment possible would only lift the back of the Pop higher -very '70s but not the look we're after. Loony would like the chassis dragging the road on airbags, but it's got to be reasonably driveable, so we'll stick with one shock position for now. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 09:53:06 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 09:55:22 AM
New chassis cross member, on the left. More for mounting stuff on than for strength.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 09:56:02 AM
The body looks deceptively smooth in photos but it's actually still very rough. A lot of work yet to do.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 09:59:06 AM
Loony & PD's funky little Bantam project. The motor's shot -I think they said "shot" anyway. Anyone got a replacement they'd like to donate?


Title: Re: Manky's Pop.
Post by: shabby on April 30, 2008, 01:17:24 PM
pop pickup looking the dog doo dars


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 02:01:07 PM
I think that was a compliment! Thanks anyway!


Title: Re: Manky's Pop.
Post by: shabby on April 30, 2008, 03:10:03 PM
that was the best of compliments ;D ;D ;D lol


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 30, 2008, 04:11:52 PM
May know of a Bantam lump will ask.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on April 30, 2008, 05:15:58 PM
tis looking a right little lowdown cracker Manky


Title: Re: Manky's Pop.
Post by: madron on April 30, 2008, 08:05:02 PM
Loony & PD's funky little Bantam project. The motor's shot -I think they said "shot" anyway. Anyone got a replacement they'd like to donate?
my mates dad got a few bantam motors will ask him and let you know asap


Title: Re: Manky's Pop.
Post by: Mr_G on April 30, 2008, 09:25:35 PM
Coming together nicely I see!


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 10:08:49 PM
"looking a right little lowdown cracker"

-who? Loony?
I think the boys finances for the Bantam project are a little limited to say the least -maybe a cup of tea & a donut. Maybe they can swap something for an engine? -like, say, PD?
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 10:10:27 PM
Just bought an ally radiator for the Pop from Ebay. 80 quid. Got to collect it from Birmingham now. Well, not right now, but sometime soon.


Title: Re: Manky's Pop.
Post by: shabby on April 30, 2008, 10:41:11 PM
was watching the rad glad you got it dude  :D ;D :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 30, 2008, 10:45:31 PM
Yeah, thanks for the shout on that.  ;)


Title: Re: Manky's Pop.
Post by: shabby on April 30, 2008, 10:50:54 PM
your welcome if i see anything else will email ya  :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 01, 2008, 11:37:23 PM
Took delivery of a set of Rover engine mounts from "Pop Browns" today.
Loony & I spent a couple of hours late this evening finishing & fitting the box section lower shock mounts. Only tack welded on for now. Just need a couple of spacers between the shock & the mount & they're done. We tried out the suspension & it works well but the springs seem a little soft. Valley Gas Speed Shop, who supplied the shocks, do one free exchange of springs so we'll probably uprate them, but will wait till the front suspension's fitted before gauging how much stiffer they need to be.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 01, 2008, 11:39:15 PM
.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on May 02, 2008, 07:43:01 AM
lookin like a roller ;D


Title: Re: Manky's Pop.
Post by: texon on May 02, 2008, 01:21:04 PM
Manky were did you get your taxi wheels from I am trying to get hold of a set of 16" but am struggling so any help would be great  ;)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on May 02, 2008, 01:51:24 PM
i think madron gave um hime and said"dont tell that Texon guy" ;D


Title: Re: Manky's Pop.
Post by: madron on May 02, 2008, 05:07:49 PM
manky can you get a close up picture of the air vent opening especially how the flap mounts on your pop when you get time thanks ron


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 02, 2008, 07:52:49 PM
Will do Ron. I'll take some snaps & measurements tomorrow.
Tex, I bought mine at the Southern NSRA swapmeet in Essex last year. A tenner a piece with knackered old tyres on, (no good for the road but O.K to build it on). They were sold to me as a matched set of 4 taxi rims, but when I got them home & looked closer, they turned out to be 2 16 inch taxi 'uns & 2 15 inchers of unknown origin. The front ones in the photos aren't actually mine -they came with a Pop axle I borrowed from Richard at Valley Gas Speed Shop to build the chassis on until I can get some machining done on my own axle. Think they might be Wolsley.
PantherShaun's on holiday for a couple of weeks but might be worth getting in touch with him when he gets back. I know he's got some taxi ones & may have spares.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 03, 2008, 09:32:28 PM
Pics of the side air vents Ron.
The openings measure 165mm tall by 55mm wide. The flap mounting plate has 2 holes, 35mm apart & 6mm diameter. Bugger -forgot to measure where the mount sits on the flap itself.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 03, 2008, 09:32:54 PM
.


Title: Re: Manky's Pop.
Post by: madron on May 04, 2008, 08:59:09 AM
thats great if you measure distance from edge for mounts will put 2 studs in no rush i know your busy


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 04, 2008, 04:02:58 PM
Thanks Ron. I'll check next time I'm there. I think the width measurement was a mill or two short of the actual hole size to allow for clearance when opening. The flap needs a radiused slight return lip on it, rather than just a flat panel please.
Just got home from Birmingham. Been to collect the aluminium radiator I bought from Ebay. Cost 250 quid to have built. I got it for 80. It came from a circuit racer -Peugeot hatchback bodyshell with Vauxhall redtop motor. It was used 5 times then they changed the racing regulations. The owner had been using an LDV van fan but kept it for the new rad. Anyone got one going spare? The Post Office use them but it's impossible to "lose" stuff from the workshops these days -too much paperwork. The Pop rad shell tapers towards the bottom. The radiator should just fit inside the top but the bottom corners might poke out either side. Fortunately I'll be running the sides of the bonnet open.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 04, 2008, 04:03:26 PM
.


Title: Re: Manky's Pop.
Post by: Trikerbob on May 04, 2008, 06:39:07 PM
Tidy radiator  :D :D


Title: Re: Manky's Pop.
Post by: twolanes on May 11, 2008, 10:01:16 PM
Good too see it in the flesh mate, its going to be awsome when finished.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 11, 2008, 10:29:17 PM
Should've had the engine in & running today. Soon, soon.


Title: Re: Manky's Pop.
Post by: twolanes on May 11, 2008, 10:34:57 PM
im looking foreward to seeing it finished mate, its going to knock peoples socks off.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 12, 2008, 09:38:25 PM
Got to be finished & registered before the end of the year when they tighten up the registration process yet again. Sounds easy enough but you can bet we'll be out there on New Year's Eve trying to finish the thing! It seemed to be well recieved at the Basingstoke show, which was a nice shot in the arm for Loony & I. Good to know people liked it.
Madron -you still here? Haven't heard from you in a while.
The side vent measurement you asked for is 7/16" from the centreline of the flap for the mounting bolts.  :)


Title: Re: Manky's Pop.
Post by: madron on May 13, 2008, 07:42:58 AM
ye still here in background v busy at moment tryin to get van on road for creatures rally plus just got a big order for kitcar company for guards etc  will put bolts in flaps for ya also on with chummy seat mould  so i can make ya 2 and bring all ya stuff too billing if ya still going


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 13, 2008, 06:20:16 PM
Yup, will be at Billing. I'll use the original steel Chummy seat in the Pop, but will certainly buy a pair of 'glass ones from you -no idea why, but you never know when you might need them!


Title: Re: Manky's Pop.
Post by: shabby on May 13, 2008, 09:07:22 PM
do you want me to take inner wing to billings  ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 13, 2008, 10:39:03 PM
Yuss perlease.  :)


Title: Re: Manky's Pop.
Post by: shabby on May 14, 2008, 06:18:02 AM
ok dude will do  ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 14, 2008, 04:16:56 PM
We'll be there for the day on the Sunday.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 01, 2008, 09:48:50 PM
Well unfortunately Mr Shabbs couldn't make it to Billing today, but Madron was there, (as well as PantherShaun), & brought back the repro Austin Chummy seat he borrowed from me. I'm using these in the Pop, but Ron's taken a mould from one to reproduce them in fibreglass -PM him if you fancy some. I've ordered a pair myself. Not sure why but you never know when they might come in handy.
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 01, 2008, 09:50:57 PM
I collected the second door repair panel from Pop Parts Plus today -they could only send the passenger one when I ordered them a few months ago as they were re-tooling for the driver's side.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 01, 2008, 09:53:36 PM
Ron had also made me a pressie. A pair of air vent covers. The Pop has flip-out vents on either side of the cowl. I've got the hinge mechanisms but not the flaps themselves. Thanks to Ron & his fibreglassing skills, I do now. Thanks Ronald.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 01, 2008, 09:59:34 PM
Also from Pop Parts Plus was this original Buick carb manifold.
My V8 Rover engine's fitted with the original twin SUs at the moment, but space is going to be limited under the bonnet due to the kicked up chassis, so I've decided to go with a 4 barrel Holley carb instead. Brock's found me a chrome plated 390 that's been sat unused on a show engine since the late 70s. It'll need rebuilding as the rubbers are bound to be perished by now of course. The Buick manifold will bolt straight onto the Rover engine & take the Holley, which will then poke up through the bonnet. My SUs are now promised to Lunatic for a future project.


Title: Re: Manky's Pop.
Post by: BikerGran on June 02, 2008, 11:44:30 PM
I like the look of those Chummy seats - just what I could do with for the rear of the new trike IF it hadn't been made to small to take them!


Title: Re: Manky's Pop.
Post by: texon on June 03, 2008, 04:20:41 AM
they are not very wide seats you might find they will fit ;)


Title: Re: Manky's Pop.
Post by: BikerGran on June 03, 2008, 10:14:08 AM
Not so much the width as the length - will have a think about it when I've got the trike - but the radiator would have to move.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 08, 2008, 05:28:51 PM
No real progress on the Pop for a while now -I'm trying to rationalise our projects & concentrate on the one that's closest to being finished, which at the moment is my trike.
The Pop's front axle was dropped off at Namco, (North American Motor Company), in Farnborough, Hants, a week or so ago. They drilled out the spring perch holes to take the repro '32 Ford perches I've got, then bored a chamfer into the radius rod ends to fit the perches. If that doesn't make any sense I'll post some piccies next time I'm at the workshop. Basically it allows us to fit the new 26" wide tranverse spring to the original Pop beam axle. It will sit directly over the axle, rather than ahead of it as the original did, which will save us 4 inches or so in the engine bay.
Next job is to fit some hubs & wheels to the axle.
There are several disc set-ups from other cars that will almost fit the Pop spindles, but all require some degree of fettling & machine work. The closest we've found so far to a straight bolt-on fit are Triumph Vittesse brakes, which is what PantherShaun's gone for on his Pop.
A chance conversation at a hotrod show at the weekend led to a follow-up email telling me of a Dutton kitcar sitting in a scrapyard in Oxfordshire that appears to be fitted with the same Vittesse parts. Cars pass through this particular scrapyard pretty quickly though so I need to get over there as soon as I can.
I've also phoned Rimmer Brothers, specialists in Triumph parts, who tell me they can sell me brand new Vittesse discs for around 12 quid each & new, (not reconditioned), calipers for £76.55, both plus VAT.
They also do alloy hubs for a whopping 106 quid each, plus VAT. That's a lot of money when you tot it all up, but it would give me a brand new brake system, which is no bad thing. I'll chase the scrapyard brakes but if that falls through & Shaun can't locate the spare pair he's been told about, it might well have to be new parts. 

 


Title: Re: Manky's Pop.
Post by: panthershaun on July 08, 2008, 07:07:46 PM
The Triumph hubs are a straight swap, even the Pop's old bearings fit the Triumph hubs, you do need to machine a spacer to locate the hub/disc correctly once the caliper is mounted but that is the only machining you have to do ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 08, 2008, 10:20:53 PM
Cool!
Latest update- Brock's been in touch with his mate who's building a Dutton type thingy & secured me a pair of Vittesse hubs & discs, condition unknown. I've got to wait a couple of weeks till he can get hold of them, but hopefully the brakes are sorted. No calipers included as far as I know, so looks like I'll be going for the new ones. Probably not a bad idea anyway. :)


Title: Re: Manky's Pop.
Post by: poprodder on July 09, 2008, 09:40:49 PM
have you seen the price of new/recon calipers!!! :o


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 10, 2008, 03:55:25 AM
76.55 each


Title: Re: Manky's Pop.
Post by: poprodder on July 10, 2008, 06:20:54 PM
i know,
i got lucky and paid i think 43 a pair, :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 10, 2008, 07:22:08 PM
Another of Brock's mates is heading to a scrapyard at the weekend & will take a look at another Dutton type kitcar they've got there. Hopefully he can liberate the complete Triumph hub/disc/caliper assemblies from that.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 24, 2008, 05:13:15 PM
Anybody remember my Pop project? Been a while since anything was done on it. Just been too busy -life in general keeps getting in the way.
Anyway, latest on the front hub/brake saga is that new forum member "Goforest" has offered me a complete set of Vittesse hubs, discs & calipers for the princely sum of 30 quid. Obviously I said yes please, so will be visiting his workshop soon to liberate them from the triumph chassis.
The Pop's still lurking in the corner of Lunatic's workshop, on the outskirts of Basingstoke, Hants at the moment. I called on the Loony Man today & found he'd got bored of waiting for me to reappear & had been tinkering. The chassis is now sitting on my own Pop front beam axle, rather than the one I'd borrowed from Richard at Valley Gas Speed Shop, thanks to Namco in Aldershot drilling it to accept the new repro '32 Ford spring hangers. About 4 inches of clearance under the nose at the moment.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 24, 2008, 05:18:40 PM
Still borrowing Richard's hubs & wheels at the moment as the Vittesse ones will need adaptors to change the bolt pattern for my taxi cab rims.
Standard Pops have the transverse spring mounted in front of the axle. By using a new shorter spring & mounting it directly above the axle we can save 4 inches or so of room, allowing us to push the axle further forward & gaining more engine bay room.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 24, 2008, 05:28:28 PM
The standard set-up also uses a "wishbone" -a V shaped linkage that locates the axle to stop sideways movement. The point of the V is in the centre of the car under the gearbox. We've used the usual rodders' practice of splitting the wishbone to make two radius rods, which will run down either side of the chassis, ending in a rose joint attached to the chassis below the doors. We're actually using the rear wishbone as it's longer. The cast ends of the wishbone have been countersunk to accept the spring perches & now need welding to the cut down rods.
Does that all make sense?


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 24, 2008, 05:39:03 PM
We've actually made a mistake here -alright, I've made a mistake, which is nothing new. The cast rod ends are upside down. They're countersunk to allow the spring hangers to pass through them, but should've been the other way up as they're offset to clear the steering linkage. The countersinks are different angles so can't just be turned over. Not a major problem, but means a little more work to correct. It'll mean the steering rod that runs across the car from one hub to the other will be a little lower than normal, which in turn means more clearance between it & the sump of the engine. If it works out O.K we'll tell people we planned it that way.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 24, 2008, 05:52:36 PM
Follow me round to the back of the cab & you'll see that Loony's been busy there too. He's added a framework of U shaped channel across the cab back & skinned it in 18 guage steel sheet. The body's a patchwork of little fill-in pieces of metal at the moment, but hopefully they can all be panel beaten into one smooth shape once they're all in place.
Anyone got a spare pair of Pop doors? Loony's had trouble filling the gaps where we cut the door tops to lower them. Would be handy if we could cut the complete door top section from another door.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 24, 2008, 05:58:09 PM
The rear corners of the cab are double curved -as well as curving around the corner, they also taper from top to bottom. Loony's got an old Mini sat outside the workshop & reckons the tops of the front wings would be a pretty good match. He's going to try & source some cheap copies.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 24, 2008, 06:07:25 PM
I really like the overall stance of Project Pop so far. It sits low enough to look pretty damn mean, but still has bags of clearance under the body, hopefully making it practical as an every day driver. We keep talking of welding the front sheet metal together & creating a one piece flip front, but might settle for welding the two halves of the bonnet together to form a single lift off panel. That would give plenty of access to the engine or allow me to run it open if I felt like it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 24, 2008, 06:14:32 PM
One of the next considerations is the radiator. I bought an ally racing one from Ebay ages ago, but it might prove too wide to fit inside the grille shell & may foul on the suspension dampers when we fit them. I might have to bite the bullet & buy a 400 quid ally one from "Pop Browns", specifically built to fit a Pop shell & cool a Rover motor. Or, as Loony pointed out, we could mount it in the pick up bed, up against the back of the cab in a purpose made housing & duct air up to it under the cab. Quite trick but might cause more cooling headaches than it's worth. It'd certainly do away with the need for a heater in the cab!
Oh, the big red box in the piccies is the new post box I made for our cottage by the way. It's in the workshop for a drop of hotrod pinstriping from Mister Loony's brush. Busy, busy!   :)


Title: Re: Manky's Pop.
Post by: TwistedPatience on July 25, 2008, 08:49:29 AM
My word he has been busy, well done Lunatic, it's gonna be one sweet ride when done.


Title: Re: Manky's Pop.
Post by: panthershaun on July 25, 2008, 09:33:01 AM
Blooming nice work guy's, looking good ;D
Andy you may find it cheaper to get Pop Browns to convert your hubs to Ford pattern and get some Minx wheels (15") I know they will be 4 stud will still look the mutt's ****


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 25, 2008, 03:24:45 PM
The mutt's butt?
I'll look into it Shaun. Erm, have you got any Minx hubs then? If I can blag some steel from SaddleBags' workshop I can get Reg, my local guy with a lathe, to produce adaptors, using new wheel studs from SpeedShack, a half hour drive from here. Trying to re-use & re-cycle as much old stuff as possible.
As Loony said, we've fitted a state of the art triangulated 4 bar linkage, with multi adjustable gas shocks on the back, & 50 year old jalopy technology on the front. It'll be fine!  :P
To be honest, I just haven't had time to help out on the Pop lately so have told Mr Loony he's got a free hand to crack on with it as he sees fit. We share similar tastes in rods so I trust him not to veer too far off plan. Got to get back to it soon as I want to get it registered before the end of the year.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 06, 2008, 06:13:29 PM
This is the pair of Triumph Vitesse hubs & calipers I've just been to Egham, on the outskirts of London, to collect from Mr Goforest. I've also got a second pair, minus the calipers, courtesy of one of Brock's mates.
Goforest works for a car restoration company whose yard is a treasure trove of part stripped Triumphs & MGs. Cost me 30 quid. I've ordered a caliper repair kit through his company, including new pistons & will buy new discs at a later date. I'm hoping Goforest will become a regular visitor to our cottage as he's offered to provide the technical guidance we desperately need to tackle the rebuilding of Taz's Dodge Charger project. So he's our new very bestest buddy.  :)
I've spoken to "Pop Browns", the Ford Pop restoration & customisation specialists, & they can machine me a pair of hub adaptors to swap from the Vitesse's 4 x 3 3/4" stud wheel pattern, to the 5 x 5" of my taxi cab wheels. Not cheap at over 100 quid the pair, but there's no-one else available locally at the moment with the machines or materials to do it. I need to strip the hubs of their bearings & post them to Pop Browns for machining. 


Title: Re: Manky's Pop.
Post by: poprodder on August 09, 2008, 10:27:07 AM
top man kris brown,
you won't be disapointed with the service.(he changed my hubs a few years ago)

one of the better suppliers in the hobby, won't sell you anything if you don't really need it.
good for advice as well.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 09, 2008, 05:22:23 PM
Yeah, I've already bought a few bits & pieces from him.
Might not need his services for the hubs now though. PantherShaun's been in touch & may have a lead on a pair of Hillman Minx rims. Very similar to my taxi cab ones, but 4 bolt instead of 5. That'll make redrilling the Triumph hubs much easier & my local mate-with-a-lathe-in-his-shed, Reg, says he can probably redrill them at work for me. Minx wheels will also take a standard Citroen 2CV tyre, which will save a few pennies.


Title: Re: Manky's Pop.
Post by: poprodder on August 10, 2008, 10:17:25 AM
and it'll bring the front down lower!!! ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 10, 2008, 10:27:00 AM
Never a bad thing -until you come up against a speed bump.
The Pop's sat on a borrowed pair of front rims at the moment. Think they might be Wolsely. The owner won't sell 'em to me, hence the need for something else. I'd really like to stick with tall, square profile, cross ply truck tyres for that 50s look, but they're not cheap.


Title: Re: Manky's Pop.
Post by: lunatic on August 10, 2008, 01:19:56 PM
Im pretty sure you'll find that the car drags along the road with 2cv tyres on it! You need to stick with something very close to what is on it. Otherwise we (you) may need to cut the crossmember out and move it back up again.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 10, 2008, 01:50:45 PM
It was just a thought as Shuan told me yesterday that they'd fit. I want tall n skinny cross plies anyway so not a problem.


Title: Re: Manky's Pop.
Post by: lunatic on August 11, 2008, 08:03:48 AM
Good! ;D


Title: Re: Manky's Pop.
Post by: mattyk on August 13, 2008, 03:31:37 PM
didnt notice this thread before you all realy are into some mentally cool stuff OH YEAH!!!!!!


Title: Re: Manky's Pop.
Post by: panthershaun on August 13, 2008, 07:39:15 PM
don't think the 2 cv tyres are that small, I will measure this weekend. Always good for a backup idea and you may need radials for the SVA??


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 13, 2008, 08:55:15 PM
Hmm, SVA's a good point Shaun.
Life's too short for boring vehicles & Mental's only a state of mind. :P


Title: Re: Manky's Pop.
Post by: mattyk on August 13, 2008, 09:10:19 PM
i hear ya mm
(twitch twitch)!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 13, 2008, 09:16:26 PM
 ;D
As you can see, I don't know any more about building stuff than anyone else here, but it's fun learning.
Grab some metal & start building something!


Title: Re: Manky's Pop.
Post by: mattyk on August 13, 2008, 09:29:57 PM
i will cant wait ta get ta me new gaff get in my garage to start mucking things up ill keep ya posted on them .maybe you could do a best cock up of the week section sure ill fill a few slots lol :)


Title: Re: Manky's Pop.
Post by: mattyk on August 13, 2008, 09:30:51 PM
i will cant wait ta get ta me new gaff get in my garage to start mucking things up ill keep ya posted on them .maybe you could do a best cock up of the week section sure ill fill a few slots lol :)


Title: Re: Manky's Pop.
Post by: BikerGran on August 13, 2008, 09:33:13 PM
Making a good start already Matty!


Title: Re: Manky's Pop.
Post by: mattyk on August 13, 2008, 09:43:44 PM
cheers biker g i assume you mean my posting twice soz forgot how ta count defo a good start lol lol


Title: Re: Manky's Pop.
Post by: BikerGran on August 13, 2008, 10:07:46 PM
 ;D


Title: Re: Manky's Pop.
Post by: poprodder on August 13, 2008, 10:10:09 PM
Hmm, SVA's a good point Shaun.
Life's too short for boring vehicles & Mental's only a state of mind. :P

i think you have to state the estimated top speed of vehicle and the tyres have to cope(ie-speed rating) so your pop will only do 60mph!!! ;) so cross plys will be fine ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 13, 2008, 10:14:55 PM
A cunning plan!


Title: Re: Manky's Pop.
Post by: panthershaun on August 14, 2008, 07:06:29 AM
not to sure that will work ??? I think to SVA a truck you need relevant tyres fitted so 2cv may not even work ::) will check out the manual ;D


Title: Re: Manky's Pop.
Post by: poprodder on August 14, 2008, 08:51:55 AM
i don't think it matters what tyres you have, did you see that rough(as it f/kin rough :o )
roadster pick up at the nats last year that had passed commercial vehicle sva!!!


Title: Re: Manky's Pop.
Post by: panthershaun on August 15, 2008, 10:46:34 AM
I'm sure someone told me that of the 5 things checked for the commercial SVA one was that it was fitted with the correct rated tyres?? but I could well be wrong and hope that I am ;D ;D I will ask my contact again.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 15, 2008, 10:13:47 PM
Tall 'n' Skinny cross-ply fitted on a borrowed 16 inch wheel.
Citroen 2CV tyre on a VW rim, (the red one). 4 inches smaller diameter.

I'll take the tall 'n' skinny ones I think.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 15, 2008, 10:56:05 PM
A few snaps of the story so far.
We shoved the front axle as far forward as we could. That gives us more room for the Rover engine, which in turn means more legroom in the cab -plus we just happen to like it that way.
The gap behind the wheel will be filled with engine & gearbox, exhausts, suspension radius arms, steering linkages etc.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 15, 2008, 11:01:06 PM
Having accidentally scrapped the original inner wings, I blagged another pair from Shabby, which have been cut down to just their top curving edge, which forms the bridging arc between radiator grille & bulkhead. There'll be a 2 inch deep sill under the doors, which'll make the body look lower to the ground.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 15, 2008, 11:23:55 PM
That's not the floor of the pick-up bed -just a spare sheet of steel. The Pop's become a temporary workbench.
Lots of bodywork still to sort -& a floor would be nice. The pick-up section will be constructed from the ribbed floor panel of a VW camper van, (I'd also like to use that for the cab floor if we don't fit carpets). The sides will also be camper van parts -repair panels for the rear arches. They'll come up level with the bottom of the windows & extend down to the level of the sills at the front at least. That'll help to make the Pop look shorter & squatter.


Title: Re: Manky's Pop.
Post by: mattyk on August 16, 2008, 10:51:20 AM
looking good manky wat rover engine r ya usin ?


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 16, 2008, 11:15:48 AM
This one. 3 1/2 litre V8. Bought locally a year or so ago for 200 quid. Early SD1 engine with maybe a P6 box. Range Rover heads with close fitting manifolds. Not entirely sure what's been done internally, (there was talk of it having seen race action), but when hooked up to a battery & fuel can it sits on the garage floor chugging away quite happily. I've now got a Holley 4 barrel carb & triangular mesh filter, sat on a Buick manifold, to replace the original SU carbs. That'll hopefully give a little more room in the engine bay.


Title: Re: Manky's Pop.
Post by: mattyk on August 16, 2008, 12:55:20 PM
thats a spanky engine and a bloody good price realy dont think it would fit in an realiant trike lol the pop will fly along .are you planning to use it as a daily trot or just take it to show off at meets ????you cant beat an old skool rod .all these boy racers with there novas and saxos that keep putting my insurance up (im at 77 a month for a vauxhall astra 3pft!!!!) should have a lookon here and build something with character  :) ;D when do you think it will be on the road?


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 16, 2008, 02:11:08 PM
I do 80 miles a day on the motorway, commuting to work & back, so not really sensible for that, but will be used for evening & weekend mileage.
It's got to be registered as a new vehicle, through the SVA, (Single Vehicle Approval), system. That's being changed in April next year to bring it into line with the rest of Europe, so I need to get it tested & registered before then. Aiming for the end of the year if possible. 


Title: Re: Manky's Pop.
Post by: poprodder on August 16, 2008, 07:54:34 PM
thats looking jolly good.
the rover in mine sits well forward, still more room for a rad with pop front than prefect(height)

cheers chris.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 16, 2008, 11:22:15 PM
I think I'm gonna have to buy a new rad from somewhere like Pop Browns -expensive, but worth it. Been wondering about making the whole front a flip job, but decided it'll look better with the top bonnet panels welded together as a lift off piece, with the grille staying in place with the rad inside it. That'll mean I can run the car with the bonnet open in hot weather if I feel like it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 18, 2008, 08:44:43 PM
Still messing with the front suspension & steering.
Bought the rose joints for the split wishbone radius arms  but not fitted them yet. Next problem is the front shocks. Most rods go with short telescopic dampers as they're simple to fit & tidy. Loony plays about with VWs a lot & thinks he might have a spare pair of Beetle ones that would suit, but we don't think we'll have the room to fit them. They need to drop between the chassis rails & radius arms, which is a gap of maybe 3 inches. That means they'd have to sit vertically, which means they'd work well but would look odd.
So we're going to try lever arm dampers. They have a cast ally body filled with oil that we can bolt to the outside face of the chassis. An arm drops from that with a linking rod which we can link to the axle. Should be a space saving solution. Maybe.
So Taz & I called in at Brock's workshop yesterday & he removed the dampers from the Moggy Minor he's stripping for his new race car. Loony wanted the back axle so we took that too. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 18, 2008, 08:49:08 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 18, 2008, 08:49:50 PM
These are the front dampers, which are quite chunky as they support the top of the king pins. So we'll probably use the rear ones which are bolted to the axle & are smaller.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 19, 2008, 10:56:54 PM
These are the rear Moggy Minor dampers. Having fitted the transverse leaf spring we need a way to control or dampen it's boinginess. So we'll mount these lever-arm anti-boinginess units to the outside face of the chassis rails, then drop a rose jointed rod down to the inside face of the radius arms. Simple & tidy.
Don't worry -it'll make sense when we've finished it. Honest. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 19, 2008, 11:19:56 PM
The radius arms that locate the front axle to stop it moving sideways. They're made from the rear axle "wishbones", (the V shaped locating rods), cut down & re-worked a little. The narrow end will have a rose joint fitted to it to locate it on the chassis. The wider end will finish in a knuckle joint that bolts to the axle. Rather than just butt welding the parts together, we've cut some lengths of round bar -they'll be welded into the knuckle joints then the arms slid over them & welded around.   


Title: Re: Manky's Pop.
Post by: panthershaun on August 20, 2008, 08:27:18 PM
looking good boy's


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 31, 2008, 12:29:12 AM
Well Mr Shaun's seen my Pop in the flesh now. We had a visit from him this afternoon, all the way from Kent. Good to see you Shauny.  ;) He brought along a pair of Hillman Minx wheels for me, as well as a pair of Pop wheels for Loony's Volksrod project.
My Pop's rolling on borrowed front rims at the moment, but we need to get the final ones on there soon so we can set the ride height up properly. I've already got a pair of Triumph Vitesse disc brake hubs, so I'll get them adapted to take the Minx wheels, then have the wheels powder-coated & fit a nice set of "pie crust" cross ply truck tyres.
So -any ideas on what colour the wheels should be? The car will be as it is now -satin black with the red & cream MMMotors logo on the doors. I'd like to run a red coachline along the doors & continuing on the top edge of the pick-up bed sides. The wheels need to pick up on one of those colours rather than clashing in something completely different. Black paint & red wheels has been done to death on hotrods so it's gotta be either cream or black. I was thinking maybe black wheels with a red stripe around the edge of the rim. Loony suggested chrome trim rings to break up the blackness of the wheels & tyres. Not sure but will have to decide soon. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 31, 2008, 12:32:35 AM
Loony's welded the radius arms up now. Here you can see them bolted to the axle with the back end propped in place against the chassis. The Moggy Minor lever arm dampers are also clamped in place on the outside edge of the chassis rails. Hopefully it should all work out quite tidily.
The ball jointed drop arm will be replaced with a rose jointed stainless rod to connect the dampers to the inside face of the radius arms.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 31, 2008, 12:35:18 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 31, 2008, 12:41:38 AM
Two of PD's nephews, (I think), were up from Cornwall for the weekend & keen to get their hands grubby. PD & Loony have donated an old CJ250 Honda to them to hone their spannering skills on.
In the workshop you can see Dave, (Lunatic Senior)'s V Dub trike, "Pscycho Triko", as featured in the Motors section of the main site.


Psycho Triko (http://mankymonkeymotors.co.uk/Trikespageimages/psycho/trike.html)


Title: Re: Manky's Pop.
Post by: panthershaun on August 31, 2008, 11:59:19 AM
Good to see you guy's, thought I was to quick for your camera Andy ;D but I see my shorts made it into a picture ::)

Car is looking good, even better in the flesh than pictures, she is going to be one mean ride ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 31, 2008, 12:32:56 PM
You're in the background of the last piccie too, looking cool with Loony.  8)
Nice to see you too Shaun.
You come on back real soon y'hear.
Thanks again for the wheels matey.  ;)


Title: Re: Manky's Pop.
Post by: brock on August 31, 2008, 11:51:05 PM
  do the wheels in gloss black, chrome nuts and dust cap, maybe wide whites


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 01, 2008, 12:01:44 AM
Mmm. Can't decide on gloss or satin for the body -should the wheels match?
Not convinced about wide whitewalls, but I quite like the narrow banded ones on the back wheels at the moment.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 01, 2008, 06:53:08 PM
These are the Hillman Minx wheels Shaun gave me & the Triumph Vitesse hubs Brock gave me.
We need to change the stud pattern to marry the two together. At the moment the hubs are 3 3/4 inch PCD & the wheels 4 1/4. I've ordered a bag of new M12 studs & chrome nuts from SpeedShack in London & when they arrive we'll grind the old studs off flush & re-drill the hubs for the new ones. Then we'll have disc brakes on't Pop.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 01, 2008, 07:02:06 PM
Have I shown you this?
The Buick inlet manifold I picked up from Pop Brown's stall at the Billing rod run earlier this year, with the 390 4 barrel Holley Carb I bought from Brock's mate Neil, the previous owner of his Black Pig race car. The triangular mesh air filter was a freebie from Brock's own spares bin.
I'm hoping this combo will give us a bit more clearance under the bonnet, & maybe perform a little crisper than the current twin SUs too. If it still won't fit inside the bodywork, I'll swap the filter for a bank of 4 velocity stacks & poke 'em up through the bonnet.


Title: Re: Manky's Pop.
Post by: poprodder on September 01, 2008, 10:17:26 PM
very nice,
be carefull with hubs as there won't be much meat left on edge!!!

chris.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 01, 2008, 10:32:18 PM
Yeah, I checked with Chris at Pop Browns. They adapt Triumph hubs in the same way then weld them from the back just to be sure.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 11, 2008, 03:44:30 PM
All the front suspension components in place now.
The 26" spring & shackles are new, sold by "Speedway", an American hotrod parts distributor, & bought through Valley Gas Speed Shop in Berkshire.
The standard Ford Pop beam axle has been redrilled to take the Speedway spring perches & the centre spring mount on the chassis is a modified Speedway one too.
The standard Pop "wishbone" locating arm has been replaced with two radius arms made from the rear wishbone. These locate the axle to stop it moving sideways. They attach with rose joints to the chassis just beyond the bulkhead.
Suspension damping is by a pair of Morris Minor rear lever-arm dampers. These are just an arm working against an oil filled piston to take some of the boinginess out of the spring. They're bolted to threaded inserts welded into the chassis legs & will connect to the inside face of the radius arms with a pair of rose jointed stainless rods which are being machined at the moment.
A very basic set-up but it's supposed to be -it's a 50s style hotrod so we didn't want anything too high tech.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 11, 2008, 03:58:21 PM
All the big heavy welds will be prettied up once we know everything works.
The wheels are 16" Hillman Minx & will be fitted with tall skinny crossply tyres once I've checked they're O.K for the SVA test. They bolt straight onto the hubs here, but unfortunately they're not my hubs! They belong to Richard at Valley Gas & were borrowed just to get the thing rolling. We'll be using modified Triumph Vitesse ones which will allow us to fit disc brakes.
Hoping to get the engine over from my garage early next week & start fitting it.
Getting there slowly!


Title: Re: Manky's Pop.
Post by: tazet on September 15, 2008, 03:23:02 PM
News hot off the text message. Manky has just texted to say the engine for his Pop is now safely at Marcus's work shop -Woo hoo! Will post more as and when I hear from him of the progress.


Title: Re: Manky's Pop.
Post by: tazet on September 15, 2008, 06:12:29 PM
Just heard it's kinda in place ish  ;D


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 15, 2008, 06:31:56 PM
;D


Title: Re: Manky's Pop.
Post by: panthershaun on September 15, 2008, 08:42:28 PM
photo's we need photo's :P :P :P :P Andy, the minx wheels are 15" mate so don't go buying 16" cross plys for them ;D ;D :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2008, 10:37:51 PM
I'll remember -I hope.
I gave the Triumph Vitesse hubs to Chris from Pop Browns on his stall at the Hotrod Drags yesterday. He's going to re-stud them for me to suit the Minx rims, then I can pick them up at the same time as my new radiator in a couple of weeks time.

Right. Piccies.

Gary Hance, a local car recovery/delivery guy & fan of classic Fords, picked up the Rover motor from my lock-up today & ferried it out to Loony's country workshop.
"Deliverhance" 01256-420445 or 07815-114062.

Loony shunted his stock of V Dubs about to make room.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2008, 10:42:40 PM
Transplant patient meets it's new donor heart.
1953 Ford Pop, say hello to 1970s 3 1/2 litre Rover V8 with Borg Warner auto box. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2008, 10:48:17 PM
Hoik it up & bung it in. Easy.
Took 4 of us, armed with an engine hoist, 2 trolley jacks, 4 axle stands & several crow bars, 3 hours to "bung it in". Heavy little buggers ain't they.


Title: Re: Manky's Pop.
Post by: panthershaun on September 15, 2008, 10:51:32 PM
christ Manky :o :o :o you gonna need more ground clearance than that :o :o :o ::) :-* and why was Loony hiding in the kitchen/office???


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 15, 2008, 11:09:46 PM
 ;D He was -supervising.
Should have over 9 inches of sump clearance when it's done -that's more than my Ford Fiesta. It's practically a gasser. We had to take off the exhaust manifolds & the engine & gearbox dipsticks but eventually, after much cursing, thumping & heaving, it plopped into place.
Loony's run out of welding gas so we couldn't weld the engine mounts in place. So for tonight we left the sump sat on the floor between the rails. Mounts are from Pop Browns in Essex & feature nylon bushes in place of the original Rover rubbers. The steel mounts need trimming to length.
The motor has to be lifted 9 1/2 inches for the mounts to line up with the chassis rails. We'll trim the bulkhead back to suit. It'll be fine. Trust me.  ;D


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 16, 2008, 09:44:13 AM
top job you lot


Title: Re: Manky's Pop.
Post by: Mr_G on September 16, 2008, 05:59:35 PM
Coming together nicely manky, loving the mahoosive mota you has squeezed in to it!


Title: Re: Manky's Pop.
Post by: Firery Fred on September 16, 2008, 07:58:34 PM
Haven't read this thread for a while, not really into 4 wheelers, but this really has me interested.Mind you if it takes as long as the trike :D :D :D :D :D :D


Title: Re: Manky's Pop.
Post by: old harper on September 16, 2008, 08:44:27 PM
tell u wot ,that pop looks the nutts .. love the idea with old skool front end etc...


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 16, 2008, 10:57:44 PM
Hello Old Harper & welcome to MankyWorld.  ;)
Thanks for the positive input.  ;D We've got a tough deadline on this one. We're going to register it as a new vehicle, through the Commercial SVA process. Unfortunately that all changes next April when the procedures are tightened up to bring them into line with Europe. So we're aiming to get this thing at least testable, if not fully finished, by Christmas. If you look at the roof you'll see Loony's chalking up the days -"130 days to go". Not long. Not long at all. Especially when I've got 2 trikes on a similar deadline!
Loony had a few errands to do today & I had to head home to Guildford, (an hour's commute from Loonyville), at tea time, so we only had time to trim back the bulkhead a little more & start blocking the motor up to the correct height. We plan to sit the engine mounts level with the chassis rails -so they run horizontally between the engine & the inside face of the chassis legs. That should mean the exhausts exit just above the chassis. Can't get the hoist in the right place to lift the motor cleanly so we're using a trolley jack at either end, lifting & adding blocks of wood till we reach the desired height.
Another 4 inches or so to go yet.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 16, 2008, 11:01:45 PM
The auto gearbox doesn't take up half as much room inside the cab as I thought it would. I imagined the shifter being way back behind me somewhere with a huge tunnel between the seats. Actually. it looks like the shifter will be a stretch forward to reach & come up maybe 4 or 5 inches between the seats. Good job it's an auto though cos there's only room for two pedals in the footwell!


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 17, 2008, 11:57:49 PM
Lots of measuring & shifting the motor back & forth this afternoon until we were eventually satisfied it was sitting central & level in all directions -thank you Loony Senior for your assistance.
We're using 2 part, nylon bushed engine mounts from Pop Browns. When we originally worked out the dimensions for the box section chassis, we decided to drop the engine between the rails. I don't know if we're cleverer than we thought or whether it's pure luck, but it seems to have worked out pretty well. We shortened the mounts down a little then welded them to the inside face of the chassis rails.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 12:00:28 AM
Never leave a camera unattended in the workshop.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 12:01:17 AM
I think I know who the culprit was.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 12:02:54 AM
Engine bolted up & the Pop dragged out into the daylight. Woo hoo! it fits!


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 12:05:54 AM
The SU carbs will be dumped in favour of a big shiny 4 barrel Holley.
Looks like the exhausts will need to curve out over the chassis & down. There's a curved bridging piece to go in under the bonnet sides, so not sure how the pipes will work around that yet -maybe straight out through it?


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 12:10:01 AM
Plenty of ground clearance under the sump. Lowest part is the nose of the grille, which is bang on 4 inches off the deck, then the chassis rails under the cab, at about 6 inches.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 12:11:29 AM
There's about 2 inches of clearance between the top of the carbs & the underside of the bonnet..


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 12:16:22 AM
Next job is to replace the temporary wooden  gearbox cross member with something a little more substantial. I've got to try & blag some more box section from somewhere tomorrow. The propshaft flange on the gearbox sits 3 1/2 inches higher than the axle diff flange, but I've got the 2 piece propshaft from the Sherpa van that donated the axle in my lock-up. We'll mount the propshaft centre bearing off the cross member at the back of the cab so that the prop runs gently downhill to the axle.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 12:17:53 AM
The evil gremlin that lives in my car.


Title: Re: Manky's Pop.
Post by: panthershaun on September 18, 2008, 10:12:40 AM
looking bloody good guy's ;D


Title: Re: Manky's Pop.
Post by: TwistedPatience on September 18, 2008, 10:47:18 AM
Seats don't look to comfy tho'


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on September 18, 2008, 01:20:56 PM
Im not much of a car guy,but that looks cool to me.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 06:26:05 PM
Thanks guys.  ;D
Seats are repro Austin 7 Chummy, bought for 25 quid the pair at an autojumble at Brooklands last year. The plan is to powder-coat them, either in black, or metallic silver to mimic aluminium World War 2 bomber crew seats, (a popular weight saving mod for 50s hotrodders & back in fashion now). The bases will be padded & covered in black leather.
If anyone fancies a pair, contact Madron on this 'ere forum, who took a mould from mine to churn them out in fibreglass.
Loony & I nipped over to Valley Gas Speed Shop this afternoon & bought a metre length of box section for the gearbox crossmember, (25 quid). Jimmi said the cost of steel has rocketed & he realised the offcuts he was giving away for 5 or 10 quid were actually costing him 30 or 40 quid, so we'll make the most of the bit we bought.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 18, 2008, 06:41:04 PM
wow that is dear!! um and will fibre glass take the powder coat temps ?


Title: Re: Manky's Pop.
Post by: Firery Fred on September 18, 2008, 07:38:53 PM
Looking great now Andy ;) ;) ;)


Title: Re: Manky's Pop.
Post by: davesatan on September 18, 2008, 07:40:05 PM
needs one of these mate
http://www.rathergood.com/elvis/


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 08:08:36 PM
No VB, fibreglass don't weld too good either.
Mr Satan, your continuing oddness never fails to amaze me.  :P


Title: Re: Manky's Pop.
Post by: panthershaun on September 18, 2008, 08:16:43 PM
Andy, don't forget that your front wheels are likely to be slightly smaller than the current one's ;)


Title: Re: Manky's Pop.
Post by: davesatan on September 18, 2008, 08:22:45 PM
No VB, fibreglass don't weld too good either.
Mr Satan, your continuing oddness never fails to amaze me.  :P
its monkey


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 08:30:11 PM
Odd.  :P
I know Shaun, I know!  :)
Opinions differ slightly in the Loony workshop, but I'd like to radius the bottom corners of the front grille panel, to follow the curve of the ribbed insert & get rid of the square bottom edge. I think it would just "flow" more like that. We can finish the cut edge with a length of round bar welded around it. That would lift the lowest point of the car by several inches.


Title: Re: Manky's Pop.
Post by: BikerGran on September 18, 2008, 09:12:02 PM
It's really beginning to look like something that's gonna take to the road!


4 inches ground clearnce - that'll be fun!  Many years ago, my dad had a Healey tickford that had 4 inches, used to get in all kinds of trouble, I particularly remember a gateway to a field car park - with a long queue of cars behind!  And once when the Fire Brigade had a hose across the road with little ramps each side - STUCK!

 ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2008, 09:31:28 PM
 ;D
It depends where the 4 inches are Bobbi -so I'm told.
The front wheels sit ahead of the grille, so hopefully should contact any ramps & speed bumps before the grille does & roll over them. High cambered roads & debris in the centre of the road, between the wheels, will be another matter though!


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 18, 2008, 10:28:39 PM
hmm mines only got 4" to the sump :( think i'll b fitting a sump guard what with all the sheep we run down :)


Title: Re: Manky's Pop.
Post by: BikerGran on September 18, 2008, 11:35:58 PM
Come to think, I've never measured mine on the trike - but I have terrible trouble with speed bumps - you the ones they call sleeping policemen?  I just have to try and scrape the exhaust s l o w l y !


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 19, 2008, 01:27:49 AM
:) the sheep i hit are still alive at the time of impact :) and generally on there side they stand more than 4"... police tend to drive around in cars/vans ....for fear of getting run over :)


Title: Re: Manky's Pop.
Post by: panthershaun on September 19, 2008, 09:52:27 AM
I've been told 4.5 inches under the sump is as low as you should go, anything more and you will get stuck.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 19, 2008, 10:19:13 AM
We've got nine inches under the sump -the grille's likely to be the problem. Hoping this car's going to be reasonably sensible to drive, despite it's looks. It sits quite low, but we've built the suspension around the car at that height, rather than dropping the body/chassis over standard running gear & ending up with it riding on the bump stops. We've got full suspension travel front & back & maximum turning circle.
Our trikes have between 4 & 6 inches of clearance under the sumps. Never really been a problem except one occasion when we had to physically lift Flap's orange trike over a particularly vicious speed hump in the gateway of a show. Not the coolest way to make your entrance. But then, he's only got around 3 inches.  :P


Title: Re: Manky's Pop.
Post by: panthershaun on September 19, 2008, 11:19:28 AM
so you've got 9 and Flappy's only got 3 :-[ no wonder he doesn't hang around with you much anymore ;) ;) ::)


Title: Re: Manky's Pop.
Post by: shabby on September 21, 2008, 04:27:50 AM
must say andy , looking the dogs doo darr's  ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Mr_G on September 21, 2008, 08:11:58 AM
Looking good andy but now the motor's in where do you put your legs?


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 21, 2008, 08:30:07 AM
I have to fold them behind my ears.
We can't get in the cab yet cos the doors are tack-welded shut so the body doesn't distort & it's full of bracing poles, (it's possible to crawl in from underneath but not to get into a seating position). So we haven't actually tried it for size yet, but there seems to be a suprising amount of space inside. By pushing the front axle further forward than it'd normally be, there's more room for the engine so it doesn't come as far back into the cab as a lot of Pops do.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2008, 11:25:58 PM
A couple of days ago we picked up a length of box section from Valley Gas Speed Shop & welded it across the chassis as a gearbox cross member. Using my bestest Blue Peter skills, I then made up a paper template of the gearbox mounting plates. I cut them out of the offcuts from the front engine mounts, (roughly 6mm steel plate). Tack-welded in place by Mr Lunatic. So now the motor's fully fitted.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2008, 11:26:30 PM
The temporary wooden cross member was tapped out & -woo hoo! The motor didn't crash to the floor. Result.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2008, 11:33:38 PM
Brock paid a visit to the workshop yesterday, (sorry I missed you Steve). He brought with him a set of tubular headers to fit a Rover motor. They'd been kicking round his workshop for ages. Hey, not bad. Prettier than the cast iron RangeRover ones my engine came with -they flow nicely along the side of the Pop body.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2008, 11:37:20 PM
They're only propped in place here. They need spacing out from the cylinder head by a couple of inches.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2008, 11:48:32 PM
So I nipped out to the local tyre & exhaust centre. Help yourself to the scrap exhausts in the skip behind the shop they said. Oh, & did you know the front tyres on your Fiesta are illegally bald?
Bugger. So a couple of assorted sized bits of tube & 119 quid for a new pair of tyres. I knew I needed them & planned to get 'em changed before Taz & I go on holiday in a couple of weeks, so not all that bad really.
I cut the nearest size tube up into 8 equal lengths. They ended up 3 inches long.
Run 'em like that? Yeah, we thought that too, but can't see them getting past the SVA inspector somehow.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2008, 11:55:01 PM
So the pipes were cut & the extra sections added in.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2008, 11:58:13 PM
I left Loony welding up the various sections. The pipes now clear the chassis rails & the body nicely. Perfect.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 24, 2008, 12:00:17 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 24, 2008, 12:03:01 AM
Oh & the drop arms are fitted to the lever arm suspension now, connecting the units to the radius arms.


Title: Re: Manky's Pop.
Post by: flc on September 24, 2008, 01:25:49 AM
Looks like your making good progress there, cant imagine having more than one project on the go, madron had 28 last time i asked  :o


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 24, 2008, 05:06:19 AM
We've got 4, 3 of which will need MSVA/SVA ing & I get seriously stressed about them all. Must admit I'll be glad when they're all done.


Title: Re: Manky's Pop.
Post by: flc on September 24, 2008, 08:18:19 AM
Yes but then you will be really bored and start another 1 or 4 :) :)


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on September 24, 2008, 03:18:32 PM
Looking good there MM,making real progress. 8)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on September 24, 2008, 04:25:45 PM
ont be long before its looking as nearly finished as the trike ;D what the hell are you going to do then ;D


Title: Re: Manky's Pop.
Post by: poprodder on September 24, 2008, 05:56:36 PM
excellent progress.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 24, 2008, 09:51:22 PM
I plan to retire & become a multi millionaire media mogul.  ;D


Title: Re: Manky's Pop.
Post by: TwistedPatience on September 24, 2008, 10:10:05 PM
Course you will ;D :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 24, 2008, 10:23:28 PM
I'm going to sell you all to Richard Branson.  ;D

So after the success of bodging up the right hand exhaust, we thought we'd bung the left hand one on.
Hmm, somethin' ain't right there.
Closer examination revealed the two headers to be completely bloody different. Not only are the 4 down pipes different shapes from one side of the engine to the other, they actually run into different ports in the collector box. Oh poo.
Much head scratching & munching of Pringles, (a garage favourite), & we had to admit we'd have to cut it up & do it again. Poop.
So the left hand header will be made up of roughly 23 thousand seperate pieces of tube.

It'll be fine. Honest.
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 25, 2008, 10:24:28 PM
Arrived at Loony headquarters today to find he'd managed to sort out 3 of the 4 pipes of the left hand header. Not only that but when I got there the motor was running. A bit lumpy -not suprising as there's only 7 out of 8 pipes & lots of holes to be filled in the ones it's got, but it fires up at the first turn of the key touch of the wires on the battery & chugs away quite happily. Result!
Now for a techy question for you lot. There's an electrical fitting in the ignition circuit we can't identify. I'll grab a photo tomorrow, but not much to see really. It's a block of clear resin, wrapped in aluminium sheet, with 3 wires going into it. One goes to, (or maybe comes from), the + terminal of the coil. One to the - terminal & branching off to the distributor & one straight to the dizzy. Any ideas? Is it a ballast resistor? Seems to be acting as a switch in the circuit as without it connected there's no spark at the plugs. Can I replace it with the coil I bought for my trike, which has a ballast resistor piggy backed onto it? It's an ugly lump of ally & resin so would be nice if we can get rid of it. My engine's a late 70s SD1 Rover by the way, with a P5 or P6 gearbox & possibly Range Rover heads.


Title: Re: Manky's Pop.
Post by: panthershaun on September 26, 2008, 10:19:13 AM
nice work guys ;D think I'd better get up the barn tomorrow and work on mine or I'm not going to make the Hayride next year for our Poptastic show down on the dirt :-\ :-\ :-\


Title: Re: Manky's Pop.
Post by: tbone on September 26, 2008, 12:15:44 PM
beware of resin compounds in silver foil, you`ll have the drug squad after you! :D
Seriuosly tho, we need to identify the distributor that you have, i believe rover experimented with 3 different ones in the late 70`s, early 80`s, this is around the time that electronic ignition was first being introduced.
So the first question is, points or no points? My guess is none. And so, does this look familier?


Title: Re: Manky's Pop.
Post by: tbone on September 26, 2008, 01:23:43 PM
an old pic, sorry
Now for a techy question for you lot. There's an electrical fitting in the ignition circuit we can't identify. I'll grab a photo tomorrow, but not much to see really. It's a block of clear resin, wrapped in aluminium sheet, with 3 wires going into it. One goes to, (or maybe comes from), the + terminal of the coil. One to the - terminal & branching off to the distributor & one straight to the dizzy. Any ideas? Is it a ballast resistor? Seems to be acting as a switch in the circuit as without it connected there's no spark at the plugs. Can I replace it with the coil I bought for my trike, which has a ballast resistor piggy backed onto it? It's an ugly lump of ally & resin so would be nice if we can get rid of it. My engine's a late 70s SD1 Rover by the way, with a P5 or P6 gearbox & possibly Range Rover heads.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 26, 2008, 10:23:37 PM
Hmm, I'll need to take a closer look at our motor tomorrow. Really not sure what we've got, but does look like that's a ballast resistor then doesn't it. Haven't even popped the cap on the dizzy yet so no idea if it's points or leccy.
We messed about with the 4 left hand pipes again this afternoon. They're never going to quite match the tight bends of the other header, but we've done what we can with the assorted bits of tube we had. I've brought them home to clean 'em up a bit in the shed over the weekend. We're thinking maybe we'll wrap them in black exhaust bandage as it'll disguise any differences in profile & be in tune with the 50s hotrod ethos.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 26, 2008, 10:29:48 PM
Yes, of course we had to fire it up again before we took the pipes off!
Sounds completely different than it did with the cast Rover headers on. Got a real bark to it. We plan to run a pair of long "Smithys" silencers, (like long "Cherry Bombs"), under the body on either side, exiting under the pick up bed tailgate.
See you on the dirt Shaun!  ;)


Title: Re: Manky's Pop.
Post by: tbone on September 26, 2008, 10:38:51 PM
The dizzy will have a number stamped into the casing, usually round the back! if thats the setup you have it sounds like its already been cannibilised. should have the six wires attached, one feeds the tacho, the other two override the resistor when you turn the engine over, giving increased power to the coil for a short burst. When the starter disengages the resistor cuts back in. would have looked like this at some point....


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 26, 2008, 10:56:02 PM
Yup, that's the resin/aluminium thingy we've got. The wires are plugged in with DIY crimp on terminals. How does the over-ride bit work? Can I use the ballast resistor I've got in the shed?


Title: Re: Manky's Pop.
Post by: tbone on September 27, 2008, 05:55:00 AM
Time to look inside the thing. NO! put that hacksaw down, i`ve got a pic somewere  ;D
The balasted ignition circuit is to improve the spark when starting.

In a nutshell, during cranking,the battery voltage drops to around 9v, due to the heavy load being drawn by the starter motor. So they use a 6v ignition coil and feed it through the ballast resistor. Therefore the coil gets a 6v feed to it because the Ballast resistor drops the voltage down. Resistance of the resistor is equal to the resistance of the primary windings on the coil.
When you turn the key and the starter engages, the starter relay or solenoid, provides another 12v feed into the resistor and due to the way its wired,the ballast resistor is "by-passed" therefore feeding 9v to the coil during cranking. As soon as the engine fires and you let go of the key, the solenoid disengages the by-pass of the ballast resistor and the coil sees 6v again.
Still not answered your question though have i....in theory, yes you can use the one in the shed.
Just have to figure out which, of the 3 wires you have left, does what, and why ony 3, a fourth would make more sense, because then...
One to + (coil)  = 9v from resistor
One to - (coil)   = Dizzy pick up (branch to feed tacho)
One to dizzy     = pick up feed   (poss 12v)
but a fourth is needed to supply 12v into the resistor


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 27, 2008, 09:45:28 PM
Hmm, I'd like to say I understood that, but I'd be lying.
This is what we've got. Distributor. No points. No discernable numbers.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 27, 2008, 09:46:37 PM
Leccy box thing.
3 wires going into one side only.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 27, 2008, 09:48:42 PM
I need to find a remote oil filter for the motor too. The standard set up sits right where we want to put the steering box, so I need to relocate it to the other side of the chassis. Or build it as a left hand drive!


Title: Re: Manky's Pop.
Post by: tbone on September 27, 2008, 10:54:10 PM
Looks to me like its being used as a junction box. i think you probably get a direct 12v feed. unless the resistor is between the white/green and red wires, that would then suply reduced current into the dizzy.
White/green wire would supply voltage from coil +
Black/white  wire would be the trigger feed ( and tacho which is no longer used) goes to coil -
red wire would supply power to the dizzy



Title: Re: Manky's Pop.
Post by: Manky Monkey on September 27, 2008, 11:08:22 PM
So can we run without it & if so, which wires should go where on the ballast resistor/coil I've got in the shed? Only one feed into the new resistor & one out as far as I remember.


Title: Re: Manky's Pop.
Post by: tbone on September 28, 2008, 05:55:49 AM
Having slept on it and bearing in mind i have no info on the currently used coil, heres what i`d do.
First, see what the voltage is at the + side of the coil, gotta assume its 12
second, confirm the voltage for the lead that goes direct to the dist, (red one?)  <12v confirms that the resistor is placed between those two connections, giving 12 volts input and ?? volts output.
( 6ish volts means you cannot use your new coil, as that was for the reliant engine and so it would output 9ish volts) Your red wire needs to be 9ish volts in order to use your new coil/resistor, In which case, you would set your new one up like so...
WHAT A CRAP DRAWING!! ok in words...
12v into one end of the RESISTOR ---other end (9v out) connect to COIL + terminal
RED WIRE (direct from dizzy) connect to COIL + terminal   (this is the power in lead for the electronic trigger)
BLACK / WHITE WIRE connect to COIL - terminal              (this is the output wire from the electronic trigger)



Title: Re: Manky's Pop.
Post by: Manky Monkey on September 28, 2008, 08:33:20 AM
Still pretending I know what you're talking about.
O.K, not a top priority at the moment, but will refer back to that when we get that far. The coil I've got was bought from a trade stall at a hotrod show, so not a Reliant one, just yer average 12v jobbie I assume. Thanks for that TB.


Title: Re: Manky's Pop.
Post by: tbone on September 28, 2008, 08:43:07 AM
you know it works as it stands so just tidy it up a bit  ;), as the old saying goes, if it aint broke dont fix it  :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 28, 2008, 07:03:46 PM
Yeah, I'd just like to swap that ugly block for something prettier that's all. Was on a local rod run today & checked out Clunk's old Rover engined sedan. He's used a resistor from a Renault. Next job on my Pop is to cobble together some sort of steering set-up. We've got the choice of 4 steering boxes. The original Pop one, A VW camper one, an earlier V Dub split screen one & a Reliant one. Steering column will probably be a mix of Morris Minor, Pop & VW too.


Title: Re: Manky's Pop.
Post by: panthershaun on September 28, 2008, 07:16:59 PM
here is said Clunks Rover


Title: Re: Manky's Pop.
Post by: tbone on September 28, 2008, 07:26:26 PM
mmmmmmm sweeeeet.
Thats the reason i dont do cars... too many nice ones about


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 28, 2008, 07:33:32 PM
42 cars on a treasure hunt type run around the Surrey countryside today. Great weather, gorgeous motors, good company. Taz & I took over 1000 photos between us so whittling them down to a sensible amount as we speak.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 29, 2008, 08:38:21 PM
Clunk's Rover engine.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 29, 2008, 08:48:36 PM
Ran a few beads of weld around the exhausts today. One of the flanges is out of line, so we'll need to slice it off, bolt the pipes up to the motor again & re-position it. No point prettying up the welds till we know the pipes are right.


Title: Re: Manky's Pop.
Post by: panthershaun on September 30, 2008, 10:45:32 AM
nice work chaps ;D
Manky, try these guy's for crossply tyres http://www.vintagetyres.com  this one seems pretty good Waymaster  ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 30, 2008, 03:51:36 PM
Will do Mr Shaun. Still got to check that crossplies are allowed in the SVA test though.
Kev Rooney, one of the rodders' voices during the SVA consultation process, was on the Surrey Street Rodders run yesterday, but I didn't get a chance to talk to him.


Title: Re: Manky's Pop.
Post by: panthershaun on October 10, 2008, 08:37:16 PM
you got a fuel tank yet Mr Manky? as I have access to a genuine Pop one ;D ;D


Title: Re: Manky's Pop.
Post by: tazet on October 10, 2008, 11:22:20 PM
Manky says yes Shaun, he's re-using the original Pop one, but thanks anyway.  ;)


Title: Re: Manky's Pop.
Post by: panthershaun on October 14, 2008, 07:41:13 PM
no problem, just thought I would ask ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 15, 2008, 11:46:43 AM
Trying to re-use as much orignal Pop stuff as possible.
Just got home from a week's holiday in Scotland, so not quite back to normal yet, but I've had a phone message from Chris at "Pop Browns" to say the new radiator I ordered is ready for collection. He's somewhere in Essex. He's also reworked my Triumph Vitesse front hubs to take 12mm wheel studs in the correct stud pattern for my Minx wheels.
I've also had a message from "Real Steel" in Uxbridge, (not too far from us). I ordered a remote oil filter kit for the Rover engine, but before it arrived we found we no longer needed it. So it's still in it's box. Need to return it to their shop & swap it for maybe an adaptor plate to fit my Holley carb to my Buick inlet manifold. Or something shiney, depending on what they've got in stock.
Really got to push on with the Pop, as well as our 2 trike projects now. The SVA vehicle registration process is due to change in ..April, I think, to bring it into line with the rest of Europe. I'm told the trike side of things won't alter very much but that the car side will be a lot harder, so I need to get this thing at least up to SVA/MOT test standard as soon as possible now.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2008, 10:14:42 PM
Starting to seriously worry we won't get this thing sorted in time now.
Today's been taken up with a trip to Harlow in Essex, to the home of Chris, head honcho of Pop Browns, to collect the super shiney new aluminium radiator. It's designed to fit inside the original Pop rad shell, using the original mounts, (which, of course, we haven't got), but has a much larger core to cool the 3 1/2 litre Rover mill. This baby cost me as much as I paid for the whole car!


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2008, 10:19:44 PM
I also picked up a thermostat switch & relay for the fan, which is on back order.
Not sure if there's going to be enough room between the radiator surround & the front axle to fit the rad' in. We've pushed the axle about 4 inches further forward than it would normally be. Hopefully, we can stretch the bonnet an inch or 2 if necessary to accomodate it without it being too obvious. We'll need to fabricate a frame to support the surround & radiator as we're not using the original inner wing panels.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2008, 10:25:31 PM
Also on the shopping list was some triangular exhaust flanges.
It's much easier to piece the system together & remove bits when needed if they're on flat, bolt-together flanges, rather than slip-on joints. Two silencers, a flange on each end of each one, plus a corresponding flange on the pipe ends, so 8 flanges & 4 gaskets.
We hooked the motor up to a battery & fuel can & fired it up this afternoon.
"Damn that's loud! We'd better try it with the Cherry Bomb silencers fitted".
"They are fitted".
Oh bugger. Better think about some extra, super muffled, silencer boxes for the test then. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2008, 10:32:39 PM
"Pop Browns" took my tatty old Triumph Vitesse front hubs & re-machined them to take new 12mm wheel studs in the correct pattern to fit the Hillman Minx wheels we're fitting on the front of Project Pop. As the new studs are quite close to the outside edge of the hubs, they've been bronze welded from the back for added peace of mind. We do the same thing on our trike disc conversions. The wheels will need the bolt holes opened out by about 1/2mm as they're Imperial, not Metric, but otherwise they fit. So now we can run Triumph disc brakes. Cool.
I've heard all sorts of opinions on which combination of bearings & spacers work to fit the hubs on the spindles. Probably one Triumph bearing & one Pop one, with a small spacer shim behind the inner one. I'll take a trip to the local bearing supplier next week & see what they recommend.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2008, 10:42:21 PM
A small brainwave from Mr Lunatic.
He's been wondering how to finish off the rear corners of the Pop's cab bodywork. Although it looks a simple enough shape, the corner panels need to curve from top to bottom, as well as around from the door to the cab back, plus it would be nice if they could end in a rolled sill to flow nicely under the body.
A big job for him to achieve with only basic shaping tools.
Solution: sitting outside Loony's workshop is an old British Leyland Mini. Hmm, those front wings look almost exactly the shape we're looking for. A pair were ordered up from the local panel suppliers while we were away on our holidays & are now sat in the workshop, awaiting carving up, expert fitting. About 30 quid each. Once the Mini mounting flanges have been cut off they should have enough flex to be persuaded to fit quite nicely. Result!  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2008, 10:43:42 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 17, 2008, 05:25:36 PM
Another road trip today -over to Uxbridge in Middlesex, (actually only half an hour or so from us). Taz & I visited the premises of "Real Steel" to return the remote oil filter kit I bought for the Rover engine. It was bought because we thought the steering box would foul the original set-up, then we changed our minds on the steering, so it wasn't needed.
So we swapped it for this little lot. I've got a 4 barrel Holley carb & what we think is a Buick manifold, although the guys in the shop today weren't sure. I needed a way of connecting the 2 together as the mounting holes didn't line up. After a bit of head scratching & measuring, they came to the rescue with a nice shiny adaptor plate. I also bought their throttle cable fitting kit, a manual choke conversion to replace the existing electric one, a new thermostat housing, a carb rebuild kit & a Holley carb rebuild & tuning manual. Hopefully with that little lot bolted together we should be able to do a straight swap with the SU carbs currently fitted, although we might wait until after the SVA & MOT tests as the present set-up is working quite nicely. Cost me 50 quid on top of the cost of the exchanged oil filter.

Loony had a quick tot up of the costs so far the other day -probably a bit more subjective than I would be. He reckoned about 1700 quid so far, which is actually less than I expected. We always say we could build one of our Reliant trikes for about a grand if we were happy to recycle & adapt old parts, no powder-coat etc, but in reality they all seem to come to around 2 1/2 thousand cos everyone wants a pretty machine, with a certain amount of nice shiney bits & bobs. I'm hoping to build the Pop for a similar cost & so far it looks like we might just do it.


Title: Re: Manky's Pop.
Post by: panthershaun on October 17, 2008, 07:54:31 PM
. The wheels will need the bolt holes opened out by about 1/2mm as they're Imperial, not Metric, but otherwise they fit. So now we can run Triumph disc brakes. Cool.

13 mm drill will do the job perfect  ;D

I've heard all sorts of opinions on which combination of bearings & spacers work to fit the hubs on the spindles. Probably one Triumph bearing & one Pop one, with a small spacer shim behind the inner one. I'll take a trip to the local bearing supplier next week & see what they recommend.

either the original Pop wheel bearings or the Triumph bearings will do as they are exactly the same ;D ;D ;D you just need a "top hat" machined to take up the difference in the oil seal and  to align the hub with the disc


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 18, 2008, 01:10:43 AM
I've got a complete set of new Triumph ones so will obviously try those first. So much to do!  :(


Title: Re: Manky's Pop.
Post by: ByzMax on October 19, 2008, 05:21:41 PM
I think you need to stop going to shows and stuff like that and just spend your spare time working on the POP. When thats sorted or your waiting for something to arrive then get you trike done and then get Taz's Trike sorted.  Otherwise you will get......stressed...... fed up ......and you won't get anything done!  You know I'm right   ;D ::)

I've got to get my Beach Bastard completed and Mrs Byzmax has said she wants a Trike of her own for next spring/Summer so I will be spending all my spare time in the garage. If I give up my social life over the next 6 months I will have the Spring/Summer/Autumn off next year! 



 


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 19, 2008, 11:52:04 PM
I know, I know!!
You're so right Byz.  :(


Title: Re: Manky's Pop.
Post by: ByzMax on October 20, 2008, 12:56:02 AM
Well with winter coming up you should have more time.   ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 20, 2008, 04:55:41 AM
Ha! It's never ending mate.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 21, 2008, 10:27:17 PM
Well, we had a look at the front hubs & bearings today. I've got a set of new bearings for the Triumph Vitesse hubs, but at least one of 'em doesn't fit as well as it should. Hmm, maybe they're for a different year, or a different model altogether. Bum. No, of course I haven't still got the receipt.
We've got an old set of Pop bearings, so tried mixing & matching the inner races & outer shells. They fitted together O.K, but didn't fit the hubs.
Alright, on to Plan B. I gathered up the hubs & all the bearings & headed for the local bearing suppliers. Make these fit this please.
They took pity on me & started measuring up. They weren't too impressed with my replacement Triumph bearings, dismissing them as suitable for trolleys & barrows, but not for a high speed road car. I ended up buying the smaller outer bearings & ordering the larger inner ones.
We agreed we've got to get systematic about this build as we're running out of time. Lots of jobs are half done. So we'll work our way from front to back, finishing each job before moving on.   


Title: Re: Manky's Pop.
Post by: brock on October 21, 2008, 11:58:20 PM
   when all else fails, make a plan  ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 22, 2008, 04:52:18 AM
There's a plan?


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2008, 12:48:51 AM
The radiator fan arrived in the post yesterday. Fits perfectly on the rad & the whole ensemble looks like it might just fit inside the standard Pop grille.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2008, 12:50:29 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2008, 12:53:36 AM
Every time Loony walks past the Pop he tries out another colour on it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2008, 12:58:33 AM
I'm seriously tempted by this one. Sort of airforce blue. Or maybe duck egg blue? (he recently sprayed some household radiators in it). I think satin or matt blue with gloss black chassis & running gear & a black outline version of the logo on the doors would look pretty smart.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 23, 2008, 08:14:00 AM
the rad/fan looks like a good fit, colours sound ok as well :) but as you now there's a few steps before that happens m8e ;D also sounds like you may be changing the logo colours :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2008, 11:14:51 AM
The logo colours of the website are never changing! -took us months to decide on those!
Taz's Charger's going to have black outline logos on the doors, on a plain battleship grey paintjob with the chrome bumpers & trim powder-coated black. So a bluey grey paintjob & black detailing on mine would make them a "his 'n' hers" pair, but with enough differences that they don't look like carbon copies.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 25, 2008, 06:24:00 PM
After getting up at 3.30 this morning, (earlier start at the Post Office on Saturdays than the rest of the week), & trudging the streets all morning I was very cold & very tired, so didn't stay long at Chez Loony today.
Long enough to say Hi to my brother, Brock, & Mrs Brock who called in to deliver a gearbox to PD & to get some drag team embroidery done by the guy who does our merchandise. Nice to see you, you two.  ;)
The front radius arms are now finished. They attach to the chassis with rose joints & locate the axle.
The hub in the photo is a standard Triumph Vitesse one. I'll buy new discs but will refurbish the calipers.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 25, 2008, 06:25:02 PM
I tried to warm up by smoothing off all the welds on the Pop's front cross member with a flap wheel on the angle grinder, but eventually admitted defeat & brought the exhaust headers home to fettle tomorrow. Having paid Valley Gas Speed Shop to produce the basic chassis for us, we then cut the front cross member out again & raised it. The spring perch is welded to it, so raising it lowers the front of the car. We gussetted it on either side for added strength, so there was a patchwork of welds to smooth out. The open ends of the main chassis legs have also been trimmed back flush with the cross member & plated over.   


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 25, 2008, 06:28:11 PM
The arse in this shot belongs to Mr Lunatic. Pull your trousers up lad! He's a tad over 6 foot tall, so it gives you some idea of the ride height of the Pop.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 26, 2008, 02:24:45 PM
Got home yesterday to find Taz had decided to help by stripping the Holley carb down ready to strip the blue anodising off & fit the rebuild kit. Jeez, I hope she knows how it goes back together!  :o


Title: Re: Manky's Pop.
Post by: tazet on October 26, 2008, 05:46:03 PM
erm  ??? 









 ;D


Title: Re: Manky's Pop.
Post by: brock on October 26, 2008, 06:51:50 PM
I pulled this off of the net just last night, we are going to strip all the anodised bits we have and maybe redo them

http://www.focuser.com/atm/anodize/anodize.html

It will strip with a quick dip in a bath of caustic soda (allegedly)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 26, 2008, 11:56:04 PM
Not sure if our carb parts are anodised. Looks like they may be painted.
Loony gave me some truck cleaner that he's used to strip anodising before & it didn't touch the stuff on our bits. So Taz very carefully used NitroMors paint stripper. Took the blue straight off, to reveal what looks like unpolished chrome underneath. Result. 


Title: Re: Manky's Pop.
Post by: brock on October 27, 2008, 12:46:29 AM
   that may be zink chromate, soft silvery yellow colour a lot of fuel parts are finished in, or maybe yellow passivated zink, I can never remember which, I think that it means a zinc surface that has been treated with a hexivalent chrome compound so the simple answer is you're right. Thinking about it all the parts on that "baby hemi" that weren't polished or chromed were painted blue, good looking engine, should have taken it when he offered it with the car.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 27, 2008, 01:02:18 AM
Well the carb's mine, all mine! harr ha, ha!
So there.
Ha! I was right for once!  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2008, 01:05:34 AM
Started looking at mounting the radiator & grille shell today.
I wasn't keen on the square bottom edge of the grille surround. It's designed to bolt to the inner wings, which we're not using, so looked sort of -unfinished. So I marked it out in white Tippex pen & we slimmed it down a little. Looks much better.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2008, 01:07:01 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2008, 01:18:24 AM
We'll bend up a framework to support the grille & hang the radiator from. I bought a length of 3/4 inch bore ERW -smaller than the trike frame stuff, but plenty strong enough for the job. The radiator needs to fit as far inside the shell as we can get it, so the framework will probably be a mix of round & flat bar for extra clearance.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 03, 2008, 11:44:11 PM
Loony's been experimenting with radiator mounts. He mocked up a hanging bracket to bolt the top of the rad to the framework we put in the other day. The frame's welded directly to the radiator shell. Today we replaced the temporary bracket with a permanent steel one, bolted through a rubber washer to the rad. Next will be a similar tube frame around the bottom of the shell with 2 side mounts for the rad.
Looks like we're gonna have to cut off both the inlet & outlet spigots from my shiny new, very expensive radiator & re-route them. The top one will foul on the fan belt & the bottom one on the axle.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 03, 2008, 11:45:29 PM
We need to stretch the bonnet panels by about 2 inches to accomodate the radiator.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 03, 2008, 11:54:59 PM
Picked up the hubs today from Reg, our friendly local garden shed lathe operator.
He's machined them very slightly to take the new bearings. The Pop ones fitted the spindles but not the hubs & the Triumph ones the hubs but not the spindles. If anyone's interested, the smaller bearings are 03062/03162s & the larger ones 07098/07204s. 19 quid per pair.
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2008, 12:03:04 AM
I opened out the bolt holes in the Hillman Minx wheels PantherShaun supplied to take the new Metric studs, we repaired the rusted valve hole in one of them & hey presto, we have wheels that fit! The new discs are on order, so soon we'll have a Pop front axle, fitted with disc brakes. Next step is to get the wheels powder-coated & get some nice tall, skinny cross-plies on them.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2008, 12:04:13 AM
.


Title: Re: Manky's Pop.
Post by: ByzMax on November 04, 2008, 01:28:39 AM
Tis looking mighty fine there Andy.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2008, 03:34:15 PM
Why thank you Mr B.  ;D
As suggested, we've cut back on the shows & rallies a bit now to concentrate on getting our various projects done for the Spring. I finish work at 2 in the afternoon, work at Loony's workshop till about 6 or 7, spend an hour driving home, then do another hour or two in the shed on trike parts. So I'm permanently knackered at the moment, but it'll be worth it when everything's finished.
Took an afternoon off from the workshop today to call in at North Hants Tyres in Aldershot, (I pass them on my way home from work). They're specialists in vintage & custom tyres & have a good range of classic cross-plies. After a chat & a wander around their stores I'm plumping for 640 or 670 x 15 black wall Excelsiors on the front & matching 600 or 650 x 16s on the back. They all work out to around 70 quid each. No point buying them till the rims have been powder-coated but they've got them all in stock. Only forseeable problem is that all road-going cross-plies are only rated to 95mph. Will the SVA guys pick up on that? Possibly. Worst case scenario, I have to take it away & bung on a set of the cheapest budget radials I can find for the duration of the test. Safety wise, I'm not planning on racing this motor & how often do you get to do 90+ on British roads these days?  


Title: Re: Manky's Pop.
Post by: panthershaun on November 04, 2008, 05:53:45 PM
sh1t thats looking good sir, you can always borrow my front wheels if you need to mate as I'm running radials, rears are more of a problem ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2008, 07:02:50 PM
Thanks Shaun, I'll take you up on that if I have to. Feel free to call in & help out!


Title: Re: Manky's Pop.
Post by: poprodder on November 04, 2008, 07:51:11 PM
Why thank you Mr B.  ;D
As suggested, we've cut back on the shows & rallies a bit now to concentrate on getting our various projects done for the Spring. I finish work at 2 in the afternoon, work at Loony's workshop till about 6 or 7, spend an hour driving home, then do another hour or two in the shed on trike parts. So I'm permanently knackered at the moment, but it'll be worth it when everything's finished.
Took an afternoon off from the workshop today to call in at North Hants Tyres in Aldershot, (I pass them on my way home from work). They're specialists in vintage & custom tyres & have a good range of classic cross-plies. After a chat & a wander around their stores I'm plumping for 640 or 670 x 15 black wall Excelsiors on the front & matching 600 or 650 x 16s on the back. They all work out to around 70 quid each. No point buying them till the rims have been powder-coated but they've got them all in stock. Only forseeable problem is that all road-going cross-plies are only rated to 95mph. Will the SVA guys pick up on that? Possibly. Worst case scenario, I have to take it away & bung on a set of the cheapest budget radials I can find for the duration of the test. Safety wise, I'm not planning on racing this motor & how often do you get to do 90+ on British roads these days?  

just put that top speed is 95mph!!!
when form filling!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2008, 08:01:36 PM
Yeah, that was my ultra sneaky plan!  ;)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 04, 2008, 08:04:05 PM
looking good there Manky


Title: Re: Manky's Pop.
Post by: ByzMax on November 04, 2008, 11:26:10 PM
Umm Putting down the top speed as 95 mph is a no no unless you have a speed limiter!!!

I was pulled up on this!!

Tyres are something ther pay a great deal of attention to. They will require them to be marked with speed/ load ratings and the relevant eu related marks.



Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2008, 12:02:26 AM
Yeah, I wondered that. Looks like I'll be building with one set & testing with another.  ;)


Title: Re: Manky's Pop.
Post by: BikerGran on November 05, 2008, 06:29:43 PM
That's seriously looking as if it might get finished sometime in the forseeable future!


Title: Re: Manky's Pop.
Post by: madron on November 05, 2008, 10:33:16 PM
Umm Putting down the top speed as 95 mph is a no no unless you have a speed limiter!!!

I was pulled up on this!!

Tyres are something ther pay a great deal of attention to. They will require them to be marked with speed/ load ratings and the relevant eu related marks.

just tell em you have 4.55 gears in axle



Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2008, 11:25:59 PM
Oh ye of little faith Bobbi!
It'll get finished -somehow.
Think I'll build Project Pop with the cross-plies, try & test it, one way or another, but have a spare set of radials standing by.
Didn't have a lot of time at Loonyville today, so settled for bending up the bottom half of the radiator grille framework. Ideally it would've been a continous loop but we need room for the fan so will have to do it in 2 parts & maybe join them with flat bar. Loony will weld it directly to the grille shell then dress the bottom of the sheet metal around the tubing.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 06, 2008, 08:10:58 PM
Mr Loony's got a sniffly snuffly cold at the moment, so not much achieved again today. I stood & watched as he did all the work, welding the bottom loop of tube to the rad' shell then dollying the cut metal edge over it & seam welding them together. The result was definitely worth spending a little time on, but doesn't really show in the pics. The trimmed down shell now looks properly finished, with the bottom rolling underneath, rather than just ending in a cut edge. A bit of flushing off with the flap wheel & it'll be very tidy.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 06, 2008, 08:14:45 PM
.


Title: Re: Manky's Pop.
Post by: BikerGran on November 06, 2008, 09:20:12 PM
Oh ye of little faith Bobbi!

No I wasn't being sarky!


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 06, 2008, 10:12:10 PM
 ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2008, 12:45:49 AM
While I'm buggering about with the bodywork, Taz has been busy stripping & rebuilding the Holley 4 barrel carb I bought from Brock's mate Neil. We've checked the model numbers & it's a 4160 390cfm with vacuum secondary. According to the websites we visited, that's ideal for road & sports use on "small" V8s, such as our 3 1/2 litre Rover. 3,500cc equals 213.5 cubic inch by the way. Taz's Dodge Charger has a 383ci motor.
I cleaned off the blue paint & lightly polished the ally body with a dab of Solvol chrome cleaner, before Taz fitted the rebuild kit. This carb's over 30 years old, but never actually been run on a car.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2008, 12:47:10 AM
.


Title: Re: Manky's Pop.
Post by: poprodder on November 19, 2008, 10:38:07 PM
hehe thats wot kitchens were made for!!! ;D ;D 8)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2008, 10:39:52 PM
 ;D I do the washing up, she does the mechanicking.
A couple of false starts on the radiator grille mounting, but I think we've come up with the simplest method now.
Today I bent a couple of 3/4 inch bore ERW tubes & notched them to sit over the front chassis cross member. I drilled the bottom of them to pick up on the bottom radiator mounts, which are welded to the frame inside the grille. So the radiator & shell will be supported on these 2 legs. Just tacked in place at the moment to check it worked.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2008, 10:44:24 PM
I'll find some 1/2 inch round bar & make up two struts, running from the top of the rad shell framework back to either side of the bulkhead, under the bonnet. That'll tie the top of the grille shell in place. Sorted.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2008, 10:50:38 PM
The bonnet needs to be stretched by 3 or 4 inches, which is about the same amount we pushed the front axle forward by. We've seperated the bonnet top panels from the side grilles. Loony will use his metal bashing skills to add a strip into the front of the top sections & the back of the side grilles. That'll save him having to rework the curves where the side sections meet the grille shell. Hopefully it's a small enough stretch that no-one will notice it unless I park next to a standard length Pop.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2008, 10:57:50 PM
Nice Autumnal sunset outside the Loony lair tonight.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2008, 11:09:41 PM
The Flapster, in for a pair of rear mudguards & a trip to the MOT station, & the MankyMobile.


Title: Re: Manky's Pop.
Post by: brock on November 20, 2008, 12:07:23 AM
   I see the Loon is still having trouble grasping the fundamentals of trike riding


Title: Re: Manky's Pop.
Post by: tazet on November 20, 2008, 08:47:26 AM
hehe thats wot kitchens were made for!!! ;D ;D 8)

It's only in the Kitchen because it was not full of fuel when Manky got it oh and it's warmer in the house  ;D Manky has been doing a lot of welding and grinding in the shed so not the best place to try and get the carb re-done.


Title: Re: Manky's Pop.
Post by: lunatic on November 20, 2008, 12:28:28 PM
   I see the Loon is still having trouble grasping the fundamentals of trike riding
Thats why it was so difficult to get it to the workshop!


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2008, 11:50:37 PM
Loony's been propping panels in place to see how they look. Looks fine to me.
The pale blue arched sections are all that's left of the original Pop inner wings. We cut off the rest & threw it away. The front edges will need a little trimming to blend into the cut-down rad shell, but otherwise they should be O.K. By the time everything's properly fitted all the sticky-out SVA unfriendly engine bits should be safely covered. The front corners of the chassis will be rounded off with the addition of tubular headlamp brackets.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 21, 2008, 12:08:40 AM
The Holley carb I want to use is exactly the same height as the twin SUs fitted at the moment, but will be taller when we fit an air filter of some sort. As the SUs seem to work, we'll probably run it as it is for the test, then poke a filter through the bonnet afterwards. Brock gave me a triangular mesh filter, but it won't fit under the bonnet, so I'm thinking maybe one of those polished circular ones, like a big funnel thingy. That'll require cutting a circular hole in the bonnet, which means it won't hinge anymore as the 2 top panels will need to be welded together.


Title: Re: Manky's Pop.
Post by: BikerGran on November 21, 2008, 07:38:57 PM
Why cant you have a hole in the bonnet but leave the hinges for and aft of the hole?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 21, 2008, 08:19:31 PM
I was thinking something like Brock's got on the Black Pig.
To allow the bonnet sections to hinge upwards the hole would have to be a large oval shape wouldn't it?
Might be easier to have it as a complete one piece lift off panel, held with Dzeutz fasteners at each corner or maybe the original Pop bonnet clips if we can make them work, or even short leather straps.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 21, 2008, 08:29:52 PM
Took the wheels in for powder-coating in gloss black today. Should be ready next Friday. Then I can get the new tyres fitted so we can set everything up to suit, although I'll have to beg or borrow some spare rims to fit a set of cheap radials to for the SVA test. I've also bought some 1/2 inch round bar for the radiator supports. The tool shop I bought it from has a lathe onsite so threaded one end of each rod to 8mm for me. I'm making up flat tabs to weld to the other ends to mount them on the car.


Title: Re: Manky's Pop.
Post by: panthershaun on November 21, 2008, 09:22:48 PM
although I'll have to beg or borrow some spare rims to fit a set of cheap radials to for the SVA test.

So you don't want to borrow mine then huh :( :( 2cv tyres not good enough for a Manky Pop then ehh ehhh :P :P :P :P ;)


Title: Re: Manky's Pop.
Post by: BikerGran on November 21, 2008, 11:40:05 PM
I'll have to beg or borrow some spare rims to fit a set of cheap radials to for the SVA test.

What size?  We've got a set of Citroen BX wheels here with good tyres on.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 22, 2008, 01:10:48 AM
15 inch fronts, 16 inch rears. Shaun, yours were the ones I was planning to nick, but it's the speed rating that's important for the SVA. Would 2CV tyres be rated high enough to cope with the Rover motor?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 22, 2008, 06:55:19 PM
Last night I made up some better bottom radiator mounts & took them to the workshop today. No pics but they're basically short lengths of tube with washers welded on either end, that will weld across the bottom of the legs I've already made. Much stronger & prettier than just a hole drilled through the tube.
I also sorted out mounting tabs on the ends of the round bars & corresponding tabs that will be welded to the radiator grille framework. This one's just propped in place, using a conveniently placed existing hole in the bulkhead. The threaded sections will be bolted through the bulkhead with a nut & big flat washer on either side. So the radiator's weight will be supported by the bottom legs welded to the chassis & the top will be braced by the 2 bars.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2008, 08:57:12 PM
It was getting late in the workshop yesterday evening so we popped the tack welded tubes back off the chassis & I took them home to work on. After I'd driven 38 miles home, had tea & fallen asleep in front of the telly, Tanya & I ended up out in the shed at midnight, measuring, cutting & welding the mounts.
We cut a pair of curving gussets from 3mm plate & welded them in place under the tube, then blanked off the open top ends of the tubes, before welding on the bottom sections that the rad bolts to.
After work today I took the completed arms back to Loony's, prettied the welds up with a handfile, then we welded them to the front of the chassis.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2008, 09:02:12 PM
There's only one radius arm fitted at the moment, which is why the axle's at a funny angle, but you get the idea. The rad mounts curve over the top of the spring without hindering it's movement & with their triangular gussets sat against the face of the chassis, will hopefully be strong enough to support a radiator full of water.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2008, 09:10:39 PM
I've posted pics of the radiator shell in place before, but this is with it actually bolted to the new mounts. Next job is to fit the top bracing bars, then see if the bonnet still lines up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 26, 2008, 11:06:51 AM
I've got to mount a numberplate on the front end somewhere but not sure where to put it. Got to be full legal size, but could be a square motorcycle sized one, (9" x 7"), rather than the usual car size, (20 1/2" x 4 1/2" I think). I'm tempted to recess it into the bottom of the grille, but seems a shame to ruin the line of the grille opening cos that's the most recognisable part of a Pop, plus it would obstruct air flow to the radiator. A lot of rodders mount it behind the grille, which is a bit iffy & I can't see the SVA or MOT guys being happy with that, plus it would still impede the airflow. There's not really room to hang it underneath the grille. Is it legal to mount it to one side? if so, where? Would it ruin the look of the front end if I did?


Title: Re: Manky's Pop.
Post by: panthershaun on November 26, 2008, 06:04:05 PM
could try the front axle, off to one side :-\ :-\


Title: Re: Manky's Pop.
Post by: TwistedPatience on November 26, 2008, 06:35:55 PM
could try the front axle, off to one side :-\ :-\

Was thinkin' the same as that.


Title: Re: Manky's Pop.
Post by: davesatan on November 26, 2008, 06:42:12 PM
could it go on the roof


Title: Re: Manky's Pop.
Post by: BikerGran on November 26, 2008, 07:08:39 PM
Where do other people put them?


Title: Re: Manky's Pop.
Post by: 53catalina on November 26, 2008, 07:22:09 PM
you could get a sticker type one, like the old e-types used. No mounting holes required  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 27, 2008, 12:49:13 AM
On the roof like a taxi sign?  :)
Not sure if the self adhesive ones would comply with SVA regs & not really enough flat surface to mount it on. Looks like it'll have to be a square one squeezed in between the side of the grille & the wheel. I know trikes are supposed to have centrally mounted rear plates & if you put it to one side, you have to have a matching one on the other side! Is there a preferred side, left or right, for mounting front plates?


Title: Re: Manky's Pop.
Post by: tbone on November 27, 2008, 06:50:01 PM
Take a look here http://www.opsi.gov.uk/si/si2001/20010561.htm#10 for your no. plate regulations


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 27, 2008, 07:03:12 PM
Thanks for that TB.
So, as far as I can make out, the front plate can be mounted centrally or to either side, but must be viewable from both head on & from an angle -for example 45 degrees. Which means if I set it on the axle between grille & wheel, both would probably obscure it from view unless I bring it out level with the grille. I suspect the MOT guys would be less picky about that than the SVA chaps, so maybe put it slap bang in the middle of the grille for the test, then move it to the side once it's declared road worthy.


Title: Re: Manky's Pop.
Post by: tbone on November 27, 2008, 07:10:27 PM
Yep, that sums up how i read it too. Seems that as long as its visable (to a speed camera ?) it can go just about anywhere, as you say, i dont think the MOT guys will be to concerned, as long as its there and readable, cant comment on the SVA cos i`ve had no dealings with them.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 27, 2008, 07:38:18 PM
Not planning on deliberately breaking any laws, but looks like a few things will be tweaked a little once the test is out of the way. To qualify for a commercial vehicle SVA, which is apparently much easier to pass than a normal car one, the pick-up bed must be at least as long as the cab. Proportionally, that's just about the length we had in mind, but they stipulate that has to be clear pick-up bed floor area, not including fuel tanks etc. Which is a bugger cos we plan to mount the original Pop fuel tank in the bed, tucked up under the rear window. So we might have to mount the tank under the chassis, behind the rear axle, like the original Pop, to give us the required bed area, then move it later. Loony reckons we should turn up for the test with just a carbful of petrol & no tank at all!   


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2008, 12:04:50 AM
We were chatting to a couple of Surrey Street Rodders members this evening. Seems the SVA test makes way for the BIVA test at the end of March. However, the testers have to be trained on the new regs so they're not taking on any tests at all during March -which means we've got just 3 months to build & register the Pop.  :o
No-one knows what's involved in the new test yet -how are we supposed to build to regulations that we don't yet know?


Title: Re: Manky's Pop.
Post by: tbone on November 29, 2008, 12:15:31 AM
Does the BIVA then bring us into line with the rest of europe? or should that be europe in line with us? Either way i cant really see that it will alter radicaly from the SVA, as surely we are currently stricter than the european guidelines.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2008, 12:26:55 AM
Nobody seems to know -that's the problem. Lots of scare-mongering going on at the moment on the forums. Like me, anyone in the middle of building anything is now panicking & racing to get a registration plate before the window closes. But as Loony & I've been saying, if we put the Pop in for testing in bare metal, we can tack weld all sorts of protective shields over anything they take exception to, then pull them off afterwards.
A bit of racing against the clock this afternoon -the pre Christmas postal rush has already started, with everyone buying their Christmasses online this year & me having to deliver it all. So I didn't finish work till 3 this afternoon. Then I jumped in the car & headed from Hampshire into Berkshire to pick up the Pop wheels from the powder-coaters in Newbury. Ooh, them's purdy! Nice clean, simple gloss black. 25 quid a wheel for shot-blasting & coating.
Back in the car, back through Basingstoke to Aldershot, to North Hants Tyres. Managed to get there half an hour before they shut & had a set of 4 new Excelsior cross-plies fitted. 70 quid each. I know it's a personal taste thing, but I think tall truck tyres on 50s style rods look cool.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2008, 05:47:10 PM
The back of the Pop chassis has become a temporary workbench/storage area! Laying underneath the car are a couple of lengths of 2 inch bore ERW tubing, which will form the rolled top edge of the pick-up bed sides.


Title: Re: Manky's Pop.
Post by: poprodder on November 29, 2008, 09:07:50 PM
looks good with tyres fitted.(what sizes?)
did they fit them on there new fitting machine?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2008, 10:25:08 PM
Sizes? Erm, 400 x 15s on the front & 450 x 16s on the back -I think. Just yer normal, run of the mill fitting machine.
There's a guy in a wheelchair who works in the sales office. I dropped the rims off at the fitting bay at the far end of the warehouse then went to the office to sort out payment. The wheelchair guy disappeared & eventually came back 10 minutes or so later, rolling one of the fitted tyres along beside his chair. Poor guy was dripping in sweat & looked absolutely knackered. I know these guys want to be independant 'n' stuff, but I couldn't watch him struggle with the other 3!


Title: Re: Manky's Pop.
Post by: poprodder on November 29, 2008, 11:42:05 PM
blimey!

thought they had a new machine-: "mount them using our hi tech touch free fitting machine"


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 30, 2008, 01:10:53 AM
Maybe they save that for the big bucks customers, or the ones who buy wheels from them, rather than the cheapskates who turn up with a bunch of powder-coated old steel wheels in the back of their car.


Title: Re: Manky's Pop.
Post by: tbone on December 01, 2008, 07:24:44 AM
Sorry to jump in fellas, found this link...http://216.239.59.132/search?q=cache:XQaeP7a5RTMJ:www.vosa.gov.uk/vosacorp/repository/The%2520IVA%2520inspection%2520Manual%2520for%2520N1%2520light%2520goods%2520vehicles.pdf+BIVA+test&hl=en&ct=clnk&cd=30&gl=uk

Maybe it can shed some light on the BIVA test for you?


Title: Re: Manky's Pop.
Post by: kustom on December 01, 2008, 07:32:18 PM
thats a big link


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 01, 2008, 07:38:52 PM
Hmm, that's going to take a bit of reading. Thanks for that TB. It doesn't actually say it'll be impossible to get hotrods through the test, but a quick glance through looks like it may need airbags, collapsible steering columns, pedestrian friendly bodywork etc. I'm sure with perseverance, it can all be overcome somehow, but will be a daunting challenge. Still hoping to get the Pop tested under the old regs if I can.
New wheels tried on to see how high/low the beast will sit. The back end's jacked up a couple of inches off the ground here.


Title: Re: Manky's Pop.
Post by: panthershaun on December 04, 2008, 06:16:40 PM
had this little missive from my excellent source......

I haven't got anything in concrete on how the SVA is going to change for cars apart from the new name 'Individual Type Approval' or IVA and it'll come into force, or the launch date is expected to be March 09. I have spoken to the press office at VOSA and I'm on the list to get any updates, having said that, the new regs are aimed at tightening up the safety standards of 'bodied vehicles' but not particularly cars, more trailers/coaches/caravans etc. I'm told that the only cars that might be effected are low volume production cars and kit car manufacturers but at this stage VOSA don't forsee any major changes to the actual SVA inspection on 'one offs'


hope this helps ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 04, 2008, 06:51:50 PM
I'm hoping to go for commercial vehicle SVA as it involves a lot less items on the examiner's check list than normal car SVA. It sounds like they're planning to bring the commercial one up to the same standard as the car one. More reason to try & get Project Pop through the current test if we can.


Title: Re: Manky's Pop.
Post by: poprodder on December 05, 2008, 11:29:54 PM
interesting.....

http://www.nsra.org.uk/newforum/showthread.php?t=18927


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 06, 2008, 12:10:54 AM
So as long as we apply for the test before the end of February we should be tested under the current SVA regs until the end of April & if the vehicle fails we'll get the normal 6 months to rectify failed items and take it for a re-test?


Title: Re: Manky's Pop.
Post by: poprodder on December 06, 2008, 09:44:23 AM
thats how i read it.  thats if they don't change there minds before then! ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 06, 2008, 11:38:40 PM
Wonder what would happen if we put the Pop in for testing half built, knowing it would fail, just to get it in the system? Would that give us another 6 months to get it finished?

The radiator's mounted in the grille shell. Had to slot the mounting holes in both the rad mounts & grille to get everything to square up, but sorted now. Hmm, a flip front radiator? The hoses would have to be pretty long wouldn't they. We need to cut the inlet & outlet spigots off the rad & reposition them to line up with the motor. Loony's visiting Brock soon, who owns a TIG welder, so hopefully he can fix 'em.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 06, 2008, 11:45:50 PM
Final grille position. It sits closer to the motor than we originally thought, so the hood panels don't need to be extended by more than maybe 2 inches. That also means the top struts are too long, so I've trimmed them down. Now I need to have the ends re-threaded.


Title: Re: Manky's Pop.
Post by: poprodder on December 07, 2008, 09:17:48 AM
excellent progress.


Title: Re: Manky's Pop.
Post by: andbolt0 on December 07, 2008, 09:47:05 AM
looking pretty damd good


Title: Re: Manky's Pop.
Post by: ByzMax on December 07, 2008, 03:08:17 PM
It  would need to be complete and stand a chance of passing otherwise the will refuse to start the test anyhow so worth just getting done and in. It need not be painted or finished but everything needs to be working.

Looking good


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 07, 2008, 06:30:53 PM
I know, I know.  ;D


Title: Re: Manky's Pop.
Post by: TwistedPatience on December 08, 2008, 06:42:52 PM
Damn KOOL ride there Andy keep at it, anything I can do just shout.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 08, 2008, 07:22:38 PM
HELP!

Need all the help we can get on all the projects! I just don't seem to have time to do anything on any of them. So much to do. The two rods that support the top of the radiator grille were too long -we'd only guessed at their length. So I hacksawed them down the other day & after work this afternoon drove the 20 miles from Basingstoke to Newbury to have the ends re-threaded. By the time I'd fought my way back through the rush hour traffic it was time to head home to Guildford. A whole day just to get two 2 inch lengths of thread cut. Progress, but very slow progress.
Between nipping out to do his Christmas shopping, Loony took a look at the British Leyland Mini front wings we plan to canabalise to create the lower sections of the cab back corners. Doesn't really show here, but he's cut away the bit the Mini headlight would normally sit in & clamped the remaining curved section to the Pop bodywork. With a little cutting, bashing & welding it will apparently be "sound".


Title: Re: Manky's Pop.
Post by: tony b on December 08, 2008, 08:19:38 PM
clever sod :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2008, 01:18:46 AM
Before it got dark this afternoon, (damn this Winter weather), Loony & I dragged the Pop kicking & screaming out into the sunshine. Our first chance to stand back & have a good look at it for a while.
I was worried the nose would look too long with the axle pushed so far forward. Looks about right to me though. I think the taller than standard wheels help. We've still got to add the sills under the doors, which will lower the body by another inch or so.
To qualify as a commercial vehicle for the SVA test, the pick-up bed has to be longer than the cab. Our cab's about 48 inches long & the bed's 53, so no problem there. We mocked up the pick-up bed length with cardboard. We decided the rear wheels should be equi-distant from each end of the bed, so the bed will overhang the chassis slightly. The top of the bed sides will be level with the swage line on the doors & the bottom will extend down to the suspension linkage rods under the chassis.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2008, 01:19:37 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2008, 01:23:27 AM
The bonnet only needs extending by about 2 inches, which shouldn't be noticable when it's done. Unlike most V8 engined Pops, where the driver ends up with half the engine inside the car & sitting where the original rear seats would be, we've managed to keep the motor on the right side of the firewall, giving quite a roomy cab.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2008, 01:25:38 AM
We clamped our cardboard pick-up sides to the chassis rails, but the steel ones will be wider -halfway between the outer edges of the body & the sides of the rear window.
Being able to stand back & look at the truck from a distance, we can see now that the radiator grille support struts need to be lower at the bulkhead end, so that they're in line with the raised swage line on the doors.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2008, 01:29:09 AM
A few measurements for those that are vaguely interested -listen up Shaun  ;)
Ground clearance under the radiator grille        5 inches
Ground clearance under the engine sump         8 inches
Roof height                                                55 inches
Pick-up bed length                                      53 inches
Pick-up bed width                                       43 inches


Title: Re: Manky's Pop.
Post by: BikerGran on December 10, 2008, 02:28:54 AM
Looking good Andy!


No you fool, I meant the Pop!


Title: Re: Manky's Pop.
Post by: tony b on December 10, 2008, 11:21:33 AM
two vw vans ,a mini a beetle,my my andy you are busy.


Title: Re: Manky's Pop.
Post by: tazet on December 10, 2008, 07:15:47 PM
They are Lunatic's. He's the guy who has the workshop that the pop is in.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2008, 08:09:27 PM
Only a couple of hours spare this afternoon, so I bent up a loop of 1 inch bore ERW tube, which will form a frame under the dashboard for the steering column & pedals to hang from. Not easy to measure & fit when the doors are still tack-welded shut.  :P
Praise indeed Bobbi!  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on December 12, 2008, 08:24:29 PM
A few measurements for those that are vaguely interested -listen up Shaun  ;)
Ground clearance under the radiator grille        5 inches
Ground clearance under the engine sump         8 inches
Roof height                                                55 inches
Pick-up bed length                                      53 inches
Pick-up bed width                                       43 inches

Noted and printed off, being taken up the barn with me tomorrow ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 12, 2008, 11:06:01 PM
Never doubted it Shauny!  :D


Title: Re: Manky's Pop.
Post by: panthershaun on December 13, 2008, 09:32:46 AM
memo to self, gotta go lower than the Manky one :P :P :P :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 13, 2008, 04:43:04 PM
 ;D We've got rubber speed bumps in the entrances to the carpark at work. I'm hoping my front wheels are far enough forward that they'll ride up over the bumps before the bottom of the grille shell makes contact & gets ripped off.


Title: Re: Manky's Pop.
Post by: panthershaun on December 13, 2008, 04:57:39 PM
the entrance to our place is raised as well and then dips down so anything too low hits, mates old mini only just scrapes in ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 13, 2008, 05:23:56 PM
When I belonged to the Morris Minor owners' club, my mate John, the only other member with a custom, lowered his saloon so far he couldn't get into the carpark at college. He had to park a mile away & walk in from there. Sometimes you gotta suffer for your art!


Title: Re: Manky's Pop.
Post by: brock on December 14, 2008, 01:05:53 PM
We had the same problem with the beetle, Brock repllaced the front number plate with a swinging one.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 14, 2008, 01:27:16 PM
Hello Mrs Brock.
I'd forgotten your Beetle -first of the Wizard Roadsters all-fibreglass bodies wasn't it? Still got it?
Loony's done the same thing in the past with various V Dubs he's worked on. Still got to find a place to mount the front plate on the Pop. I think we'll just screw it to the radiator grille for the SVA test, then side mount it between the grille & wheel afterwards.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 14, 2008, 05:24:28 PM
The struts that hold the top of the radiator grille meet the bulkhead at an angle, but obviously need a flat surface to bolt up to. Rather than just winding the nuts up till the bulkhead's pulled flat, I've used a couple of M8 nuts, 2 washers & an off-cut of Reliant exhaust pipe to make a couple of captive nut thingies. I'll cut suitable sized holes in the bulkhead, screw them onto the ends of the struts & weld them in where they touch, then sand off the tube flush with the bulkhead, giving us recessed mounting points at the same angle as the struts.


Title: Re: Manky's Pop.
Post by: tbone on December 15, 2008, 11:35:40 AM
HELP!

 The two rods that support the top of the radiator grille were too long -we'd only guessed at their length. So I hacksawed them down the other day & after work this afternoon drove the 20 miles from Basingstoke to Newbury to have the ends re-threaded. By the time I'd fought my way back through the rush hour traffic it was time to head home to Guildford. A whole day just to get two 2 inch lengths of thread cut. Progress, but very slow progress.


Looks like you own/ have access to a tap & die set, so why did you have to mess around with these rods and not do them yourself?


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 15, 2008, 05:42:37 PM
I've got a couple of taps -6, 8 & 10mm, which I use regularly, but no dies. Cheaper & easier to pay someone a tenner to cut them for me than to buy the relevant die. In the end we cut them at 8mm, so the 10mm rods were turned in a lathe first, which I also haven't got.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 16, 2008, 10:24:06 PM
.


Title: Re: Manky's Pop.
Post by: panthershaun on December 17, 2008, 08:19:30 PM
whose a clever monkey then :P :P :P :P :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 17, 2008, 08:36:01 PM
Me is  :D
Loony's gone down with a festive cold so Get Well Soon matey -why am I saying that! He's broken his laptop too.
We're really gonna struggle to get this 'ere project into the registration process in time, so once Master Lunatic's cleared his current workload I'm going to engage the services of himself & PD for a while to push things on a bit.
How's yours coming on Shauny?


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 18, 2008, 01:17:14 AM
This evening's mystery objects-
a couple of hours of hacksawing & welding & filing in the shed tonight produced these.
Chassis outriggers. They'll weld either side of the chassis, just under the doors & support the framework under the dashboard that the steering column & pedals will hang from.


Title: Re: Manky's Pop.
Post by: poprodder on December 19, 2008, 02:48:44 PM
more progress!!! will be finished in no time.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 19, 2008, 08:47:31 PM
Sometimes I think that -then other times I start mentally totting up the jobs that need doing & realise I need another couple of years at least to get it done.  :(
My weekend off work now, so I won't be back at the Loony Lair till Tuesday. So I've brought back some homework. I've got the loop of tubing that will fit up under the dash, plus those outriggers, so my mission is to bodge expertly & seamlessly join the 2 together.


Title: Re: Manky's Pop.
Post by: poprodder on December 19, 2008, 09:27:09 PM
better than my progress, all i'm doing is buying parts!!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 20, 2008, 12:02:22 AM
Money's not the problem with my build as most of it's recycled or adapted. Just need more time.


Title: Re: Manky's Pop.
Post by: gpz on December 20, 2008, 12:27:40 PM
why when u have a spare minute dont u build a time machine then u will have all the time u like  good idea


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 20, 2008, 04:13:17 PM
If I could build a time machine the trikes, Pop & Charger would all already be finished wouldn't they
-& I'd have won next week's lottery.  :P


Title: Re: Manky's Pop.
Post by: ByzMax on December 20, 2008, 07:38:36 PM
Err slight problem with the time machine. It would take forever to finish it!  ;D


Title: Re: Manky's Pop.
Post by: tazet on December 20, 2008, 09:34:34 PM
 ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 25, 2008, 11:41:44 PM
This is the frame that will fit under the dash to give us something solid to mount the steering column & pedals to. Doesn't show in the photos, but the top section is angled forward to follow the lines of the bulkhead. It'll mount to box section outriggers that will weld to the chassis.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 25, 2008, 11:55:02 PM
Rather than just butt weld the tubes to the outriggers, I've welded slugs into the tube ends & will drill the chassis sections, drop the slugs through them & then weld around them. A much stronger joint -makes sense cos I don't want to pull on the wheel as I clamber out of the car, or push too hard on the pedals & have the mounts break.
Unfortunately I drilled one set of holes with the hole saw & my drill finally died. It's been making odd noises for a while now. Looks like I'll be treating myself to a new one in the January sales. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 01, 2009, 01:24:42 AM
New drill bought -9 quid from Argos. It'll probably last a week & I'll have to go & buy another one, but I was able to finish hole-sawing the outriggers this evening. Dropped the tubes into them, welded them in then blanked off the holes. Flushed off with a sanding pad on the angle grinder & you'd never know they were there. Of course, no-one else will ever see these parts as they'll be under the car, but I'll know everything's good 'n' solid.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 01, 2009, 01:26:16 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 05, 2009, 12:11:56 AM
Bulkhead frame thingy finished, with the welds cleaned up. This shows just how narrow Ford Pops are. We've got to get a gearbox tunnel & two pairs of boots between these uprights. A good reason for going for an automatic box -there's only room for two pedals.


Title: Re: Manky's Pop.
Post by: BikerGran on January 06, 2009, 12:06:57 AM
I was going to say I don't remember my old Anglia being that narrow but then I don't remember a transmission tunnel - was the whole car perched on top?  There was even room for a foot-operated dipswitch in mine!


Title: Re: Manky's Pop.
Post by: andbolt0 on January 06, 2009, 12:25:52 AM
you could always wear winkle picker shoes long thin and pointy  your feet would be further back giving  more room between the uprights just a thought


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 06, 2009, 07:35:26 PM
Yeah, I was thinking a pair of short stilts.
The original Pop chassis, when we started stripping it. God, that was last October.  :(


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 06, 2009, 07:36:25 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 06, 2009, 07:49:24 PM
Called at Loony's place after work today, but having spent all morning trudging the streets delivering letters in -6 degrees, I really didn't feel like doing much. Neither did Loony. He's compiled a list of jobs that need doing that runs to 2 sides of A4 paper. We've actually got most of the parts we need, it's just a matter of getting stuck in & glueing it all together.
Slotting the frame I'd made through the welded up door window & into place was a bit of a challenge, but it fits perfectly. Only propped in place here. It'll sit a couple of inches higher when it's welded in place.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 06, 2009, 07:59:22 PM
We'd originally planned on pedals that hang down, fitted to the frame I've just made. Looks like it'll be a lot easier to go for ones that mount to the floor though. VW Beetle ones are like that, but they connect to pushrods that push forward into master cylinders mounted on the bulkhead. We want ours to push backwards into cylinders mounted under the floor. Got some old pedals of unknown origin we might be able to adapt & I'll try & pull the pedal assembly out of our donor Reliant over the next couple of days too. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 07, 2009, 03:43:28 PM
Been out in the frozen wastes of the stable yard, pulling the pedal box out of Taz's Reliant donor car. No idea if they're any more useable than the ones we've got, but they'll give us a choice anyway.
Also liberated the windscreen washer bottle & pump while I was there.


Title: Re: Manky's Pop.
Post by: panthershaun on January 08, 2009, 10:17:42 AM
I'm thinking of using a 2cv peddle box on mine, comes with a split braking system which you need for the SVA.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 08, 2009, 09:16:30 PM
Hi Shaun. I'm guessing a dual feed master cylinder will do the same job -seperate feeds to front & back brakes. Presumably the Citroen set up has an integral master cylinder? We want to tuck the cylinder under the floor, below the driver's seat, as I don't want modern stuff poking into the engine bay to spoil the period hotrod look.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 08, 2009, 10:47:48 PM
Just opened the mail & the universal joint for the steering column's arrived. Ordered it from Pop Browns yesterday afternoon. Also ordered two 4 inch lengths of splined rod. I'll cut the splines off one end of each, then have them machined down to fit inside the tubular Morris Minor & Ford Pop steering columns, thus neatly splicing the two together.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 13, 2009, 01:11:19 AM
Been at the Loony Lair again today, despite it being my week off work, (I work in Basingstoke, where Mr Loony works, but live 30 miles away in Guildford).
I was determined to get the steering set-up sorted today, but as usual it wasn't to be.
This is the Morris Minor steering column I nicked from Brock's donor car for the body of his drag car. The brown bit is the original Pop steering column as you can see in the 2nd photo.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 13, 2009, 01:17:16 AM
At the base of the Pop column is a steering box. The column fits into the left side of the box in this photo. This takes the turny roundy motion of the steering wheel & changes it into a swingy back & forth motion. The arm on the steering box connects to a rod which in turn connects to the back of one of the front wheel hubs. The two hubs are connected by another rod, so when you turn the steering wheel, the steering box arm moves back & forth, pulling the connecting rod & turning the front wheels. A very simple, but robust set-up used in various forms on all early cars until the advent of rack & pinnion steering & now popular with builders of traditional hotrods, (that's us  :) ).
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 13, 2009, 01:30:45 AM
We plan to relocate the Pop steering box below the right chassis leg, alongside the engine. We'll turn it through 90 degrees, as shown in the photo, so that the arm moves sideways, across the car, instead of back & forth along it. A connecting rod will run across under the front of the engine sump, (good job we mounted the motor nice & high), & hook up to the left-hand wheel. An original Pop rod connects that wheel to the other one, so as we turn the steering wheel, the front wheels will turn. "Cross steering", (connecting the steering box to the opposite wheel), helps reduce bump steer we're told.
Without photos that probably sounds really confusing, but trust me, it'll work very neatly -we hope.
So first job was to remove the old Pop steering column from the box so we could shorten it & connect it to the Minor column via the universal joint. All was going well as we drilled out the rivets -until the aluminium casing cracked.
Bugger.
Then we noticed one of the mounting lugs was also badly cracked.
Bugger, bugger.
So, having eventually removed the column, I had to jump in the car & nip the 20 miles up the road to BKI Welding in Newbury, Berks. I've used these guys for years. They've had a hand in creating specialist crankcases for a local guy who's hobby is joining two or more bike engines together to build multi cylinder specials, so they're pretty hot at ali welding. The various cracked areas were welded while I waited, for the princely sum of 15 quid. Good as new. Brilliant. The above photo of the box is after I'd driven back & smoothed the welds off with a handfile. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 13, 2009, 01:36:03 AM
While I was waiting for the weldist to do his thing, I nipped round to the local tool shop & bought the bolts for the front brake discs.
I've had a pair of new Triumph Vitesse discs on back order for ages now, but still waiting for them, so I gave the old ones to my mate Reg, who's skimmed them as best he could. They're not wonderful, but useable. So now I've got a Ford Pop front axle, fitted with Triumph Vitesse hubs, modified with larger Metric studs to take Hillman Minx wheels, running Vitesse disc brakes.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 13, 2009, 01:47:11 AM
So a small step forward & a potential disaster averted thanks to some remedial welding.
The Vitesse brake calipers should fit neatly inside the 15 inch front wheels, but need refurbishing, using the rebuild kit I bought a few months ago. I'll draw up a template for caliper mounting plates, similar to the ones we use on the Reliant axles, & post it off to FLC, who's said he can mill them for me.
I've brought the steering box home & will mock up a mounting bracket in cardboard before transferring it to 3mm steel plate. It'll probably take the form of a triangular box with captive nuts, welded to the underside of the chassis. 
A little more progress every day.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 14, 2009, 01:23:24 AM
Spent the whole evening making a cardboard template for a bracket to hold the steering box to the underside of the chassis. In the end it took both Taz & I, using our best Blue Peter cardboard & sticky tape skills to produce something that we think will work. Maybe. It'll pick up on the 3 mounting points on the aluminium casting. All I've got to do now is reproduce it in 3mm steel plate.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 15, 2009, 01:25:14 AM
Been in the shed making that bracket, using an offcut of the chassis box section. I know it wasn't a huge job but I was in tinkering mood so locked meself in the shed, bunged some blues on the CD player & wound the volume up loud & happily hacksawed & filed & welded till supper time. Result, one distinctly average looking bracket, but it'll do the job.
Not an easy thing to describe, but there are two captive 8mm nuts welded inside it. The bolts pass through lugs on the steering box & bolt into the bracket. There's a third threaded hole on the steering thingy but the thread's knackered so I'll retap it to 10mm then it'll bolt to the bottom edge of the bracket. The whole thing will be welded to the underside of the new Pop chassis.


Title: Re: Manky's Pop.
Post by: InsolentMinx on January 15, 2009, 11:55:28 AM
looks a bit flimsy... will the sellotape hold up to the rigours of your driving?


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 15, 2009, 12:06:21 PM
Don't be silly, you can't build stuff from cardboard & selotape.
I'll reinforce it with a couple of elastic bands.


Title: Re: Manky's Pop.
Post by: poprodder on January 16, 2009, 12:25:06 AM
no washing up bottle or double side sticky tape!! :o ::)


Title: Re: Manky's Pop.
Post by: tazet on January 16, 2009, 01:20:40 AM
Oh yes he used those too but not on this part.  ;D


Title: Re: Manky's Pop.
Post by: InsolentMinx on January 16, 2009, 03:07:05 PM
hehe.

they look great
best to use an elastic band too though juuuuuust in case.


Title: Re: Manky's Pop.
Post by: ByzMax on January 16, 2009, 11:23:59 PM
Andy have you checked the SVA regs for steering columns?

not sure from the picks exactly what you planning and this is off the top of my head but Your UJ must have be set an angle that it allows the lower rod to deflect it in the event of impact and you must I think have a collapsable section in it too.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 17, 2009, 12:07:27 AM
I'm sure you're making these things up Byz!  :P
Yup, we're ahead of you on the collapsible column thing -planning to weld in the honeycombed collapsible section from an old VW. Haven't heard of the other one though.
I've got the phone number for Kev Rooney, one of the consulting committee members when the SVA test was instigated. I'm drawing up a list of questions for him at the moment.
Good news on the test front. The commercial SVA will run until October 2011. Woo hoo!


Title: Re: Manky's Pop.
Post by: flap on January 17, 2009, 11:17:02 AM
2011!! bet its still not finished  ;D :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 17, 2009, 11:19:01 AM
Git.
You joining us for the MonkeyWorld run this year Mr Flap? How about the Basingstoke Transport Festival?


Title: Re: Manky's Pop.
Post by: flap on January 17, 2009, 11:39:01 AM
Hopefully will be on both of them.


Title: Re: Manky's Pop.
Post by: ByzMax on January 17, 2009, 12:23:50 PM
Ok that's cool. That's good news about the commercial vehicle SVA. Takes some of the pressure off so you can get your Trike sorted for the summer and not rush the Pop.  ;D


I hope to b e ready for the Basingstoke Transport festival. ;D (Hope being the operative word)




Title: Re: Manky's Pop.
Post by: Manky Monkey on January 17, 2009, 01:45:57 PM
Great! We'll see both you gents there then.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 19, 2009, 12:47:30 AM
Stripped down a set of Triumph Vitesse king pins today. The calipers are destined for the Pop, but when I took off the mounting plates that go with them, their 4 mounting holes look very similar to the Pop ones. What's the chances they'll bolt straight on? I'll let you know tomorrow.


Title: Re: Manky's Pop.
Post by: poprodder on January 19, 2009, 08:00:02 PM
Stripped down a set of Triumph Vitesse king pins today. The calipers are destined for the Pop, but when I took off the mounting plates that go with them, their 4 mounting holes look very similar to the Pop ones. What's the chances they'll bolt straight on? I'll let you know tomorrow.
[/quote]

any news on whether they bolt on?
very interested!!! ;D ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on January 19, 2009, 08:19:18 PM
and me ;) oh come Manky one and tell us :P :P :P :P  just a thought ??? as Odgie has built the shedster will yours be the Mankster ::) ::) ::) :P :-*













I'll get my coat ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 19, 2009, 08:54:11 PM
I liked the Manksters. Herman was my favourite  :D
Loony borrowed my welder over the weekend to do a little job offsite. I thought he was doing it on Sunday, but it was this afternoon, so I couldn't get into his workshop to find out. I'll be there tomorrow afternoon, so watch this space!


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 21, 2009, 12:37:17 AM
Nope, they're not a straight, bolt-on fit I'm afraid.
Looked promising though, even when we were holding the Vitesse caliper mounts & looking at the Pop hub. Not far out, but enough that they couldn't be adapted. We cable-tied them in place to see what was needed.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 21, 2009, 12:43:01 AM
The central hole was too small & the 4 mounting holes about half an inch too close together, but so close! The lugs the caliper bolts to are too thick too. We guesstimated we could probably make new ones from flat plate, incorporating the Pop mounting holes & the Vitesse caliper mounting holes. So it was time for another paper template.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 21, 2009, 12:55:51 AM
No responsible adults around to supervise me so I had to take a chance with the craft knife. Managed to survive with all my digits intact. Then we realised we didn't have any suitable steel plate.
So I jumped in the car & headed 20 miles up the road to BKI Welding in Newbury, Berks to blag a bit of 6mm steel.
These guys are great & I've got no hesitation in recommending them -if you need any welding/fabrication done & you're in the Newbury area, give them a try. As I've said elsewhere, they welded up the specialist crankcases for a local guy who married 2 bike engines together to build a V8 bike. The same guy's currently building a bike using a Dodge Viper engine -yes, really! BKI have done some welding work on the engine & also sliced up a pair of Viper car wheels & joined the outer edges together to form a bike rim. Clever guys.
Anyway, I wandered in, clutching my scruffy paper template, & they not only guilotined 4 squares of 6mm steel plate for me while I waited for a whole 2 quid, but then used their very scary metal chomping punch thingy to nibble the edges off to roughly the right shape -that'll save me a few hours hacksawing & cost me a fiver. Thanks chaps  :)
So tomorrow I'll chain drill out the centre hole, drill the mounting holes & clean up the edges, then we'll see if they actually fit. 4 bits of plate equals a pair of plates for me & a spare pair. If they work, do either of you guys want the other pair?   


Title: Re: Manky's Pop.
Post by: tony b on January 21, 2009, 02:07:34 PM
whats a chain drill ,andy


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 21, 2009, 04:27:58 PM
 ;D Sorry Tone.
"Chain drilling" -to drill a series or "chain" of smaller holes around the inside edge of the marked large circle, gradually increasing the drill size until the holes break through into each other, thus removing the material in the middle. If I had a hole saw of the right size I'd use that, (like a circular hacksaw that fits in the chuck of a drill). If I was a little cleverer than I am, I'd drill a large hole in the middle then use an electric jig-saw to cut outwards from there. If I was posh I'd plasma-cut it. Being a stoopid Luddite, (look it up), I'll stick to drilling lots of holes then filing out the bits in between. 


Title: Re: Manky's Pop.
Post by: tony b on January 21, 2009, 04:49:16 PM
thats what i done on some of my bits until my mate said he had a plasma cutter,i still had to file it all up though.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 21, 2009, 05:11:30 PM
I'm old school -I actually quite enjoy creating stuff with just hand tools. Also, by the time I've run around sorting out a better way of doing it, I could've done it by hand & saved the hassle.


Title: Re: Manky's Pop.
Post by: panthershaun on January 21, 2009, 05:45:54 PM
If they work, do either of you guys want the other pair?   

Yes please Andy  :P :P :P :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 21, 2009, 05:50:44 PM
Thought you might! I'd better get out in the shed & start drilling then.


Title: Re: Manky's Pop.
Post by: panthershaun on January 21, 2009, 05:53:09 PM
nice chap ;D ;D ;D I'm occupied full time for a few day's getting ready to receive and then mail out the next issue of BC so don't think I'll be Hotrodding for a couple of day's  :'( :'(


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 21, 2009, 10:28:40 PM
I'd better reserve my copy with Lunatic then. Anything good in the new issue?  :)


Title: Re: Manky's Pop.
Post by: tbone on January 22, 2009, 05:15:17 PM
hmmm, dont suppose you made a note on the dimensions of the vitesse caliper mount brackets did you?


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 22, 2009, 06:51:02 PM
Which ones? The new Manky ones, or the originals?


Title: Re: Manky's Pop.
Post by: tbone on January 22, 2009, 06:54:34 PM
the originals...


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 22, 2009, 07:06:27 PM
Still got them at Loony's place. Haven't thrown them away. What's the problem?


Title: Re: Manky's Pop.
Post by: tbone on January 22, 2009, 07:43:45 PM
not so much of a problem, more of a `could be an easy fix`. I`m looking for caliper mounts for an mgb axle, took some measurements yesterday and drawn up a preliminary sketch but before i take hacksaw to steel, bit of a long shot, old triumph, old mgb, what do you think the chances are they may fit my flange?


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 23, 2009, 09:09:32 AM
I haven't seen your flange,  :o  but it's worth a go isn't it. Shaun's using Triumph Spitfire hubs on his Pop. Don't know if they're the same as Triumph Vitesse, but might give you a second option. Mine are at Loony's place. I'll be there tomorrow so will bring them home. If they work for you, you're very welcome to them.


Title: Re: Manky's Pop.
Post by: tbone on January 23, 2009, 10:11:29 AM
okey dokey, centre hole size isn`t so much of a problem as i`ll probably have the hubs machined to suit the discs, fingers crossed the other six holes may line up  :-\


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 23, 2009, 02:47:22 PM
Just had a visit from Janie & Dave_Postie, on their way to visit Chevy Rick. Nice to see you guys.  ;)
Dave's had a clear out of his spares stash & brought me over a pair of brand new 3" chrome peep mirrors for my Pop. Still in their bags, 5 quid the pair. Thank you very much! They're intended to clip on the tops of the door frames, but with luck I can adapt them to fit on the top door hinges. Pop hinges are very ..sticky outy, & mine have already been drilled for mirrors by a previous owner.
Thanks Dave.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 23, 2009, 07:00:25 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2009, 10:50:29 AM
Hadn't noticed that those mirrors are both right hand ones. Not sure if they're reversible, but if not I'll just use one & keep the other as a spare. Decided to fit it on a mount welded to the top of the driver's door frame.
The caliper plates are made & fitted in place with some temporary bolts. It was only a scruffy paper template, so I had to slot the mounting holes a little to line them up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2009, 10:57:20 AM
6mm flat steel plate brackets. They need a spacer between the back of the plates & the calipers to centralise the caliper over the disc, but they only need to be the thickness of one & a half washers.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2009, 10:59:51 AM
Time to try the wheel in place ...phew! They fit & spin quite happily without fouling on anything.
Sorted.  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2009, 11:04:41 AM
One of PD's mates arrived with a Monkey bike in the back of a van. 6 foot 2 & 15 stone & he plans to get it road legal & commute to work on it. It'll fit in his locker at work! He'd tried everything to get it running though, without success. 5 minutes of PDness & it was chugging away quite happily. Obviously PD had to give it a roadtest.  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2009, 11:13:07 AM
The doors of the Pop are still welded shut at the moment, keeping the body solid until we get some decent framework inside it. We've started work on the steering though so need to work out steering column angle, clearance for pedals etc. Someone was going to have to squeeze inside. With a 3 inch roofchop the windows are now too low for me to climb through -yeah, chubby Monkey.  :(
So Loony clambered in. I'm 6 foot. He's about 6, 2, but reports it as being suprisingly roomy. With a passenger, it'll be shoulder to shoulder as Pop body shells are quite narrow, but lengthwise, not bad. One thing we hadn't realised -if we put the seats right back against the cab rear panel, the view through the chopped screen is quite restricted. Pulling them forward a few inches improves things. It'll also give me room to stuff a jacket down the back of them!


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2009, 11:26:35 AM
The footwells are a little snug but as we're using an automatic gearbox, there'll only be 2 pedals, which will be operated with the right foot, switching between the 2. Enough room for both feet but it'd be a squeeze trying to operate a clutch pedal as well with big boots on.
We want to keep the steering as simple as possible. The universal joint I bought from Pop Browns to join the Pop shaft to the Moggy column will angle to a maximum of 30 degrees. Any further & we risk it binding as it turns. So we thought we might need 2 UJs, to give us the correct angle. Turned out 30 degrees is spot on, with the UJ & shafts clearing the engine & exhausts nicely. That's handy.
We tried the Bakalite Ford Prefect dashboard in place. It fits straight into the Pop shell. The steering column will hang 4 or 5 inches below it. Can't go any lower or the wheel will make climbing into the seat very awkward.
Also propped the standard Rover P6 auto gearstick in place. We're going to make up a bracket to bolt it directly to the top of the gearbox, then cut the gearbox tunnel around it, with a covering plate. Gearstick position seems fine.
So all in all, looking O.K  :)


Title: Re: Manky's Pop.
Post by: poprodder on January 25, 2009, 11:55:14 AM
hi,
excellent progress, caliper mountings look good, is 6mm thick enough? was going to make mine outa 10mm!!! but don't think theres enough room then for mounting bolts.
looks like loads of room inside, rodders haunch methinks!!!     lol



Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2009, 12:23:50 PM
The stresses are rotational, rather than lateral -when you brake, the plates try to turn with the wheel, rather than trying to bend across their width. So 6mm should be fine.
Even with the roofchop, there's still plenty of room for a jaunty hat.  :)


Title: Re: Manky's Pop.
Post by: panthershaun on January 26, 2009, 05:35:10 PM


Take the screw out the back and then reverse the arm and re screw the mirror back on














I think ??? ;D
Just had a visit from Janie & Dave_Postie, on their way to visit Chevy Rick. Nice to see you guys.  ;)
Dave's had a clear out of his spares stash & brought me over a pair of brand new 3" chrome peep mirrors for my Pop. Still in their bags, 5 quid the pair. Thank you very much! They're intended to clip on the tops of the door frames, but with luck I can adapt them to fit on the top door hinges. Pop hinges are very ..sticky outy, & mine have already been drilled for mirrors by a previous owner.
Thanks Dave.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 26, 2009, 09:11:13 PM
Ahh, right. Looked at that but wasn't sure & didn't want to pull them apart unnecessarily.
We've had another look at the UJ thing & decided to go for 2, as clearances will be very tight with just one. It'll also allow us to shift the steering column & wheel across toward the centre of the cab a little more, as it would otherwise sit very close to the door. The UJ I bought from Pop Browns looks like a Ford one used on a variety of vehicles, including early Escorts & the like. Loony knows a local firm who specialise in restoring old Fords so we'll see if we can blag another one from them. It'll be good to get the steering done as it's one of the last big headaches to get sorted out.
TBone, the original Triumph Vitesse caliper plates are in the post to you mate.  ;)


Title: Re: Manky's Pop.
Post by: tbone on January 26, 2009, 09:20:29 PM
aww thank you very much boss.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 26, 2009, 09:24:42 PM
No problem -a bit more clutter out of our shed!  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 28, 2009, 11:59:46 PM
Finally got round to seperating the other section of bonnet top from it's side panel. A few fillets added here & there & it'll be fine. I think we'll end up welding the 2 top sections together as a single lift-off panel.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 29, 2009, 12:31:36 AM
When I was planning to build a '27 T roadster a couple of years ago, I bought a scrap Leyland Sherpa van to rob of it's axles. In the end I went for the Pop instead, but saved the Sherpa rear axle & prop-shaft. The axle's gone under the Pop so obviously the back end of the prop-shaft fits it. By chance the front U.J has exactly the same bolt pattern as the Rover engine -well, not really a coincidence. British Leyland produced both Rover & Sherpa & some Sherpa vans were fitted with Rover V8 engines.
The Sherpa prop is a 2 part one. 2 shafts with the joint between the 2 supported by a rubber "donut". Rather than creating a single shaft from the 2, we've opted for the easier route of shortening both ends & keeping the "donut" & sliding joint in the middle. With some careful measuring the support bracket sits directly under the chassis cross-member at the back of the cab.
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 29, 2009, 12:34:45 AM
The seats will be sat on runners, which will lift them by around 4 inches, bringing the seat backs up level with the back window. That'll also bring the seat bases up level with the prop shaft.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 31, 2009, 12:21:24 AM
The back section of prop is sorted now, with the universal joint tack-welded in place. The front U.J needs machining down a little to fit inside the tube end -a job I'm hoping Twisted Patience can sort out. Once everything's tacked together I'll have the prop professionally welded & balanced -worth it to cut down on vibration caused by it being out of balance.


Title: Re: Manky's Pop.
Post by: poprodder on February 01, 2009, 12:46:35 AM
excellent progress.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 11, 2009, 01:50:31 AM
Been pottering about in the shed over the last few days, making a propshaft loop. This'll be welded into a cross member on the chassis & sit upright between the seats, with the propshaft passing through it. A sensible precaution. Also a necessity if we ever decide to go racing I think. If the propshaft ever breaks loose it'll flail about inside the cab at several thousand rpm. Not good. The loop would restrain it, at least until the car had skidded to a halt.
I couldn't bend the ERW tube in a tight enough bend for a full 180 degree hoop, so made it this semi oval shape instead.
Take a few offcuts of toob. Bend em, slug 'em together, say the magic words Izzy wizzy, let's get busy, then spend a few evenings filing it all smooth. Of course, it's another part that no-one will ever see, but I'll know it's there.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on February 11, 2009, 01:54:25 AM
nice its almost jaffa cake shape :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 11, 2009, 11:31:26 AM
More Polo mint shaped Id've thought.


Title: Re: Manky's Pop.
Post by: texon on February 11, 2009, 02:15:51 PM
but if valley ate all the centres out of your jaffas you could be seeing the shape of things to come  ;)


Title: Re: Manky's Pop.
Post by: tazet on February 12, 2009, 12:40:21 AM
Hey Texon. Good to see you're still lurking about. How's your pop going?


Title: Re: Manky's Pop.
Post by: texon on February 13, 2009, 02:15:21 AM
stood at the mo weathers s**te :( but I can smell good weather a commin ;) I call in almost every day on here just to keep up on the good news as its always bad on the tv and we all need a boost each day a few projects on here are coming along great keep up the good work all ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 13, 2009, 10:32:56 AM
Nice to know you're still about mate. Well if we're uplifting the Nation's spirits I'd better get back in the shed then.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 13, 2009, 08:23:52 PM
Not much to report today. Spent the whole afternoon trying to figure out how to fit a manual choke conversion to the Holley carb I'm going to fit to the Pop. It's a genuine Holley conversion kit, but comes with vague written instructions & no diagrams, plus some of the parts are for 4 barrel carbs like mine & some for 2 barrel. So it took several hours of head scratching, but I think it's right now. Seems to be a million different levers & cams & stuff on both sides of the carb body & I'm not entirely sure which does what!
We'll probably put the Pop through the SVA test with the current SU carbs on as they seem to work, then change afterwards. I'm thinking probably just a plain round chrome air filter, poking through the bonnet if necessary. The carb's supposed to sit level to the ground, but obviously doesn't at the moment. Not sure if the valley between the 2 rows of cylinders is angled. If not we'll have to make up a tapered spacer plate to level things up.
The chrome plated carb came from Neil, the guy Brock got the original Black Pig drag car from. Plated parts were one of many options available. I'm told it's a late 70s unit that's never been used. Taz stripped it down for me & fitted a rebuild kit from Real Steel -who needs a missus who can cook & clean when you can have one who's happy to rebuild engines! The manifold is a second-hand one from Pop Browns. I was told it was from a Buick, but there's no manufacturers marks on it & a couple of people have said it may be an unknown aftermarket one.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 13, 2009, 08:24:19 PM
.


Title: Re: Manky's Pop.
Post by: poprodder on February 13, 2009, 10:30:15 PM
was expecting to see it on kitchen table!!! ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 13, 2009, 10:42:48 PM
It was.  ;D Then I took it to an exotic location to photograph it, (less washing up in the background in the shed).


Title: Re: Manky's Pop.
Post by: tazet on February 13, 2009, 11:31:13 PM
But after the shed for the photo shoot it moved to the spare bedroom for a nap. It's hard work being a photography model you know.


Title: Re: Manky's Pop.
Post by: poprodder on February 15, 2009, 08:58:43 PM
you can get a low level filter for 4barrels.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 15, 2009, 10:15:26 PM
That would be worth a look. Any idea who stocks them?


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 17, 2009, 06:47:58 PM
Another small step forward & a matching one back again today.
Loony & I have worked out the steering set-up for the Pop & confirmed with Brock, knower of all things, that it'll work. It involves re-using the original Pop steering box, mounted up front on the right-hand chassis leg, with a short section of the Pop steering column running back towads the cab & linked via a universal joint to a Morris Minor steering column.
Fine. So I've cut down the Pop inner column. The outer sleeve that normally surrounds it, also locates it into the steering box, so we need to keep a short length of that, with the fittings from either end.
So I found someone with a lathe today to machine the two ends of the inner shaft so they'll slot together, so I can weld them up. Great. Unfortunately, when he clamped it into the chuck of his lathe, he tightened the jaws onto the nut that retains the ball bearing race in the outer sleeve & ping! -it promptly snapped in half.
Bugger. So now I need a ball bearing retaining nut with a very fine cycle thread, (yes, I've already tried the local cycle shop), for a 50 year old car. Anyone got the fittings from a 1953 Ford Pop steering column they don't need? 


Title: Re: Manky's Pop.
Post by: poprodder on February 17, 2009, 07:10:39 PM
http://www.roadcraftuk.co.uk/index.asp?display=SubCategory&Col_Category=Accessories+%26+Chrome&Col_SubCategory=Air+Cleaners


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 17, 2009, 07:16:10 PM
That's not a steering column nut ...ahh, I see. Yup, I like that Mr Gasket Lo Rider air filter. 14 inch diameter, which sounds quite big, so I'll have to measure up the car. Thanks Sir.
I think I may also need an angled base plate to level up the carb on the manifold. Do you know of anyone who sells those? I've tried Real Steel but they can't help.


Title: Re: Manky's Pop.
Post by: poprodder on February 17, 2009, 07:35:26 PM
i think i've some bits left, will have a look when i'm next over there(you in a hurry!!!)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 17, 2009, 07:52:11 PM
Thank you. Yeah, always in a hurry! Taz has posted a wanted ad on the NSRA forum too. I want to get the steering set-up sorted over the next week or so if I can. I've ordered some rose joints & threaded inserts n stuff for the drag link & they won't be in till next week.


Title: Re: Manky's Pop.
Post by: brock on February 17, 2009, 09:55:56 PM
Did you try McGill Motorsport for the inserts and stuff ? normally next day and cheap


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 18, 2009, 12:02:04 AM
No I didn't. Vaguely remember you telling me about them.
I need a left hand & a right hand 10mm rose joint with male threads, plus matching locking nuts, plus a pair of M10 threaded inserts & a metre of suitable tube to weld them into. Failing that, a length of solid bar & someone who can cut M10 threads on the end might be easier.


Title: Re: Manky's Pop.
Post by: brock on February 18, 2009, 12:56:34 AM
                              http://stores.ebay.co.uk/McGill-Motorsports


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 18, 2009, 02:51:44 PM
Rose joints ordered & on their way & McGill Motorsports added to the Links for Commercial Purposes list.


Title: Re: Manky's Pop.
Post by: TwistedPatience on February 21, 2009, 11:48:02 AM
I have been modifying a few parts for Andy's Pop,thougt it was only right I put up photo's.

Have been machining one of the UJ's for the prop shaft.


Title: Re: Manky's Pop.
Post by: TwistedPatience on February 21, 2009, 11:50:40 AM
Question for  you Andy, is the dimension of 45mm going to be a TIGHT FIT in the tube? It should be

I could really do with the tube it is going to fit.


Finished at 45.07mm



Title: Re: Manky's Pop.
Post by: Manky Monkey on February 21, 2009, 04:42:32 PM
Hi Doc.
Ahh, now I can see it -the snap you sent to my mobile phone was so tiny on my screen that I couldn't really make it out.
Yes, that's a good fit measurement. The prop shaft's about 3 feet long with a joint in the middle so a bit awkward to post to you!


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 21, 2009, 05:18:04 PM
Another tiny step forward yesterday.
Loony's busy prepping a V Dub camper van for paint at the moment, so I'm doing all the small jobs I can till he's done. I've been bringing homework back from his workshop to do in my shed. The Pop inner steering shaft is now shortened & welded back together, cut down from about 3 feet long to about 10 inches -why did I file it nice & smooth? It's going to be hidden inside the outer sleeve. Anyway, next job is to attach a universal joint to the end of it. I bought a steering UJ from Chris at Pop Browns. So yesterday I hopped in the car after work & drove 20 miles up the road to Newbury in Berks to a local tool shop. They have a small lathe in the back of the shop & for a couple of quid machined the end of the splined shaft that came with the U.J until it slots inside the end of the steering shaft. I'll weld it up & also drill & pin it just to be sure.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 21, 2009, 05:38:24 PM
The steering box will be welded to the underside of the right hand chassis leg, just forward of the engine mount. It's then connected to the wheel on the other side of the car by a linking rod. This is known as cross steering & is apparently the best set-up for minimising bump steer. So after a bit of juggling of parts, I scribbled down some measurements & headed for a welding shop while I was in Newbury. They let me blag their off-cuts of steel, so I picked up a 650mm length of 16mm diameter mild steel bar for a fiver. Then it was back to the tool shop for them to cut 10mm threads on each end while I waited. The rose joints had arrived from McGills, (great service -less than 18 hours from the other end of the country), so I could screw them onto the ends of the bar. Back to LoonyLand to try it all in place.
Woo hoo! it fits! The 2 front wheels are joined by a rod called the "cross link". The steering rod is called a "drag link", (correct me if I'm wrong guys), & should ideally follow the angle of the cross link to avoid the steering being heavier in one direction than the other. So as the cross link lays horizontal to the ground, the drag link should too. With the steering box held in place under the chassis, we measured the distance from the ground up to each end of the rod. Bang on 10 inches both ends, so it'll sit perectly horizontal. Cool!
Next job is to weld the UJ splined fitting in the end of the steering shaft & fit the outer sleeve to the steering box. Then we can tack the box in place on the chassis, attach the drag link & work our way up to the steering column & steering wheel inside the car.
I wouldn't have a clue how to go about this from scratch -looked at loads of hotrods at shows but never really studied the steering geometry. Working through it all bit by bit though, it's all making sense now.


Title: Re: Manky's Pop.
Post by: poprodder on February 22, 2009, 11:11:01 PM
thats some excelent progress.
seems like you've got everything ok, have you got caster angle set?
are you going to run a panhard rod on the front,as you've split the wishbone?

cheers chris.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 23, 2009, 12:13:58 AM
Splined shaft to accept the Universal Joint, welded into the end of the shortened steering column shaft.
We're running 7 degrees of castor, as recommended by Jimmy Hibberd at Valley Gas Speed Shop.
With the transverse spring attached to both the front beam itself & the chassis, it can't really move sideways, so shouldn't need a Panhard rod should it? :)


Title: Re: Manky's Pop.
Post by: poprodder on February 23, 2009, 06:34:57 PM
could sway and shimy on shackles.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 23, 2009, 11:28:53 PM
Hmm, I'll look into it Chris.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 24, 2009, 05:51:57 PM
O.K, looked into & agreed -yes, we do need one. Here's an explanation, found by Brock elsewhere on the 'net.

 http://www.srbymichael.com/help/pete5-1.pdf

Basically, there's a certain amount of sideways movement in the spring shackles, (has to be, otherwise the spring wouldn't be able to move). When cornering, it's possible for the weight of the car to move sideways on the shackles. As one end of the steering drag link's attached to the steering box, which is in turn attached to the chassis, if the car body moves sideways, so will the drag link, pulling on the cross link & increasing the amount of turn. So the car would turn further into the bend than intended -not a good thing.
Easily cured though. A panhard rod is a length of round bar attached to the chassis on the same sid as the steering box & running across to attach to the opposite side of the axle itself. Hopefully I can use a couple of 8mm rose joints I have spare in the shed to attach one end of a 1/2" round bar to the front corner of the chassis, running under the spring perch to attach to the inside face of the axle somewhere near the spring shackle. According to the diagram in that link, the panhard rod needs to be parallel to the drag link to ensure their ends move in similar arcs to eliminate bump steer. So ours will need to sit horizontally,
Thanks for the heads-up on that Chris. I don't pretend to be an expert -I've never built a hotrod before, so this is all an interesting learning curve.  ;)


Title: Re: Manky's Pop.
Post by: brock on February 24, 2009, 09:30:28 PM
                "....attached to the chassis on the same sid as the steering..."

  is this the same sid as has the dragster ?


Title: Re: Manky's Pop.
Post by: panthershaun on February 24, 2009, 10:02:40 PM
Could be Sid Little, haven't heard much from him recently  ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 24, 2009, 10:12:34 PM
Don't you just hate smart erses.  >:(


Title: Re: Manky's Pop.
Post by: panthershaun on February 24, 2009, 10:13:17 PM
Only when they repeat on you  :P :P :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 02, 2009, 06:07:54 PM
While Taz & I were at the NSRA swapmeet in Essex yesterday, I picked up another Pop steering column & steering box for a tenner. Actually I mercilessly haggled the seller down to £9.58 -all the loose change I had in my pocket at the time. An expensive way to get the nut I need to replace the broken one, but at least I'll have a spare steering box as well.
You can see how much I've shortened down the column here, ready to connect up to the Morris Minor shaft.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 02, 2009, 06:14:01 PM
I need an M10 tap to cut a new mounting bolt thread in the side of the steering box. Bought this rather natty boxed set of taps & dies at the swapmeet for 20 quid.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 02, 2009, 06:16:56 PM
I also found a new air cleaner for the Holley carb for 8 quid, plus chatted to a guy doing CNC machined parts, who can make me an angled carb spacer block if I need it, to level the carb up once it's fitted.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on March 02, 2009, 11:39:02 PM
sounds good so far then keep at it m8e


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 03, 2009, 12:05:33 AM
Came across this Ford Prefect front end at the swapmeet. Transverse spring, lever arm dampers, panhard rod...  bugger. Beaten to it -by about 50 years or so.
Well at least we know we're on the right track then.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 06, 2009, 03:14:11 PM
Thanks to big brother Brock, the panhard rod's made, using a length of tube with threaded inserts in each end to take left & right handed 10mm rose joints. We've also re-made the drag link in tube as I'm told it's much stronger than solid bar.
Haven't had much time to spend in the shed lately but this morning I finished knocking up a drop bracket to attach the panhard rod to the front of the chassis. The rod needs to run horizontally, the same as the drag link, so needs to lay 3 inches below the chassis so that the other end can attach to the axle. Now I can go back to Loony's workshop & measure up for the mounting on the axle end of the rod.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 06, 2009, 05:24:45 PM
Stripped down the spare steering column I bought at the swapmeet to retrieve the conical nut that locates the ball bearings.
Old nut. New nut.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 06, 2009, 05:29:44 PM
Fitted the shortened outer sleeve into the steering box, drilled & tapped the joint between the 2 & pinned the sleeve in place with 3 short 6mm allen bolts.
Then I screwed in the inner shaft, popped in new ball bearings & fitted the conical nut & lock nut. Steering box sorted.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 06, 2009, 05:30:08 PM
There's an upcoming trend in the custom bike world at the moment for "steam punk" -mock Victorian engineering. I think this box, with it's rivets & stuff, looks like it could've been part of a Jules Verne creation.  :D


Title: Re: Manky's Pop.
Post by: TwistedPatience on March 06, 2009, 08:42:50 PM
There's an upcoming trend in the custom bike world at the moment for "steam punk" -mock Victorian engineering. I think this box, with it's rivets & stuff, looks like it could've been part of a Jules Verne creation.  :D

A so fashion has caught up with me again!


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 07, 2009, 04:10:20 PM
We follow where you lead Doc!  8)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 07, 2009, 09:51:29 PM
Called at Loony's after work today & checked the panhard rod will fit where I want it to. No problem, so we measured up for the mounting boss to be welded to the axle to take the other end -check your emails Doc, I'll send you the dimensions later.
Loony & PD had to work on a customer's car with the workshop roller shutter door open the other day in a torrential downpour. I was quite shocked at how rusty the front of the Pop was today. Hopefully it's just surface stuff & will come off when the parts are shot-blasted & powder-coated.
It'd be nice to get all the front end fabrication finished, so back in the shed at home this evening, I made a start on the headlight mounts. The lights are actually tractor units, bought at a steam rally last year for a tenner each brand new. They have dip & main beam, plus a side light & proper patterned lens. Slightly smaller than original Pop lights.
I'll mount them in short lengths of ERW tube, with a captive nut welded in the top. The wires will run down inside the curved arms. The arms are over-length at the moment. They'll probably be as long as the unpainted bits when they're done & will be welded to the front corners of the chassis, which will help soften the pointy corners.   


Title: Re: Manky's Pop.
Post by: poprodder on March 08, 2009, 08:43:33 AM
hi,
more progress, well done.
cheers chris.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 09, 2009, 05:06:31 PM
Taz was working yesterday, (Sunday), so I'd intended to spend a leisurely afternoon, pottering in the shed. Unfortunately the pottering gods had other ideas. We had a howling gale here yesterday with intermittant rain & minus temperatures. When I went out to the shed I was greeted by a large chunk of the roofing felt flapping in the wind. So my afternoon was mainly spent up a ladder, tacking it all back down & slapping a thick coat of bitumen on it.
I did manage to get the headlight brackets done, but had to work very late into the night to do it, (sorry Taz, won't happen again, honest  :-* ).
First I took the nuts that came with the lights & welded them into the ends of the short upright pieces of tube to form captive nuts for the lamps to screw into.
Next I decided the bottoms of those tubes should be domed rather than boringly flat. Not having access to a lathe or milling equipment, I had to improvise, so stacked 3 different sized washers on top of each other & tacked them all together. A thick bead of weld around each & half an hour of angle grinding & filing produced a pleasingly shapely bottom.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 09, 2009, 05:09:17 PM
I plan to run the lighting wiring down inside the light brackets so had to drill a 13mm hole in the side of each mounting before they were welded to the arms.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 09, 2009, 05:14:45 PM
Mountings welded to the curved arms & tidied up. The arms are over-length at the moment cos I wasn't sure how high they had to sit on the car. This afternoon I called at Lunatic's workshop & tried them in place. Loony's busy painting a camper van at the moment so I wasn't allowed to make any mess, so I brought them home again to shorten & notch so they'll slot over the corners of the chassis. 


Title: Re: Manky's Pop.
Post by: TwistedPatience on March 09, 2009, 05:47:34 PM
I do like a "pleasingly shaped bottom" ;D

Nice work Andy.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 09, 2009, 07:27:57 PM
Knew you would Doc.  ;)
Did you get Taz's email with the dimensions for the panhard rod fitting?


Title: Re: Manky's Pop.
Post by: TwistedPatience on March 09, 2009, 08:28:46 PM
Yep should be done by the weekend.


Title: Re: Manky's Pop.
Post by: panthershaun on March 09, 2009, 08:41:09 PM
Mountings welded to the curved arms & tidied up. The arms are over-length at the moment cos I wasn't sure how high they had to sit on the car. This afternoon I called at Lunatic's workshop & tried them in place. Loony's busy painting a camper van at the moment so I wasn't allowed to make any mess, so I brought them home again to shorten & notch so they'll slot over the corners of the chassis. 

Cool as mate, really cool.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 09, 2009, 10:27:59 PM
Why thank you Shauny  ;D
Doc, you are truly a gent among gents.  :-*


Title: Re: Manky's Pop.
Post by: tony b on March 10, 2009, 09:36:13 AM
andy,hope you dont mind mate but ive been strugling to mount my rear lights and ,da dah,youve just solved the problem ,these look the poodles privates mate,can i ,ahh go on let me.
tony,shabba


Title: Re: Manky's Pop.
Post by: TwistedPatience on March 10, 2009, 12:59:09 PM
Panhard Rod fitting done! ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 11, 2009, 01:23:16 AM
The poodle's privates? Where do we get these blokes from?  :D Be my guest Tony.
Mr Twisted, I think I love you.  :-*

Took the headlight mounts over to Loony Towers after work today & we tacked 'em in place. They sit over the corners of the chassis & help to round it a bit -don't know why we're bothering to make it pedestrian friendly, the wheels would mow them down long before they grazed themselves on the chassis. Anyway, after a little tweaking & bashing wiv a big 'ammer, they seem to sit more or less level, (the grille shell & radiator are on slotted mounts & not set true & square here by the way). 


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 11, 2009, 01:33:10 AM
I couldn't bend the tube for the mounts any tighter than it is & was a little concerned they sat too high & wide on the car. Haven't got a copy of the Construction & Use regulations to hand, even though we don't have to comply with the lighting regs for a commercial SVA test, so we measured all the cars outside the workshop & took an average height measurement. These are exactly the same height as my Ford Fiesta lights & about 250mm in from the edge of the vehicle. Should be fine. They can also be seen from 45 degrees from the front of the vehicle. Not sure if that applies to headlights, but it does to indicators.
With the bonnet propped on & the side panels held in place by my lovely photographic assistant, plus imagining the exhausts exiting between the side panels & chassis rails & running back under the body, everything fills out a bit more & the lights look much more in proportion.
It's starting to look like a proper car now.  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 11, 2009, 01:43:59 AM
Spurred on, & while we had the welder fired up, we tacked the modified Pop steering box to the right hand chassis leg. With the drag link attached to it & to the cross link, we turned the shaft in the end of the box & -whoa! the wheels turn! That's almost like proper steering! Damn we're good!
Next job is to hook the Pop shaft up to the Moggy Minor steering column & wheel we blagged from Brock. That involves an intermediate shaft & a second universal joint, blagged from one of Loony's mates, who's into off roading Range Rovers. I hopped in the car & nipped over to Newbury in Berkshire to Unimaster Components -a tool shop & hydraulic hose specialist, who have a small lathe in the back of their shop. While I waited, they machined the end of the Rover shaft to take the end of the splined shaft that came with the UJ already fitted to the steering box. Following this so far? Back to the workshop & Loony welded the 2 parts together for me to take home & file nice & smooth.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 11, 2009, 01:51:57 AM
Getting me to wait in their shop is damn sneaky of Unimaster I reckon -it's chock full of all manner of wondrous tools. I invariably end up entranced by the shiny things. They know if they leave me there long enough I'll buy something. Sure enough, although they only charged me a fiver to machine the shaft, I spent another 15 quid on a couple of boxes of mechanic's gloves, a set of feeler gauges, a protractor & a wonderful little hole gauge -a wickedly pointy thing with measurements marked on it. Stick it in a hole & it'll tell you the diameter. Utterly unnecessary, but it was pretty & cost 2 quid. 


Title: Re: Manky's Pop.
Post by: brock on March 11, 2009, 08:06:57 AM
  I've got one of those, they are dead handy at times, they used to be given away as advertiseing by someone, I'll have a look tonight if I remember. Oh, and Unimaster are brilliant.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on March 11, 2009, 11:58:36 AM
That pickup is the bollox Andy ;D It looks ferking wonderful ;D


Title: Re: Manky's Pop.
Post by: SUMO on March 11, 2009, 12:40:37 PM
just read the thread through from the beginning [quiet day at work...] spot on - looks boomin lovely


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on March 11, 2009, 02:01:13 PM
I think it would look cool with a wooden back end. 8)


Title: Re: Manky's Pop.
Post by: panthershaun on March 11, 2009, 05:48:50 PM
lights look crap Andy ::) ::) not in keeping with the car at all :-\ :-\ :-\

Tell you what, as a good mate I will take them off your hands for you ;D ;D ;D ;)


Title: Re: Manky's Pop.
Post by: tazet on March 11, 2009, 07:29:43 PM
What to go on your tepid rod. I think not  ;D


Title: Re: Manky's Pop.
Post by: TwistedPatience on March 11, 2009, 07:39:13 PM
"Tepid Rod"...............  I'll hold the coats


Title: Re: Manky's Pop.
Post by: tazet on March 11, 2009, 08:32:05 PM
 ;D Either that or Luke warm rod  ;D

Yup Doc get our coats  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on March 11, 2009, 08:40:25 PM
 :P :P :P :P :P :P :P  we'll see who has the hottest rod  :o :o :o :o shall I rephrase that  :-* :-* size isn't everything  ;)


Title: Re: Manky's Pop.
Post by: tazet on March 11, 2009, 08:43:13 PM
Size isn't everything! Well you are a bloke so you would say that wouldn't you.  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on March 11, 2009, 08:48:20 PM
 :-\ :-\ :-\ I'm cut to the quick  :'( :'( :'( :'( how could you be so hurtful :'( :'( :'(
































 :P :P :P :-*


Title: Re: Manky's Pop.
Post by: tazet on March 11, 2009, 08:52:35 PM
 ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2009, 01:07:49 AM
Shaun, you're discussing size with a woman who owns a 6 1/4 litre V8 Dodge!
Mine's more of a Grot Rod at the moment, but it's getting there slowly.
Only an hour or so free to play in the shed this evening, so I welded & cleaned up the steering linkages.
We're using a Morris Minor steering wheel & column, supplied by Brock. It has a large M for Manky on the horn push.  :) The standard Moggy indicator stalk has a light on the end that flashes green. I was going to use an old "Banjo" style early Moggy or Land Rover wheel I picked up at an autojumble -it has 3 spokes, each made up of 3 wires. I decided the current one looks more truck like though.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2009, 01:21:45 AM
So. The modified Pop steering box has a splined end welded onto it's shaft, to hook up to a universal joint bought new from "Pop Browns". On the other side of the joint is another splined section welded into the end of a Range Rover shaft. That pushes into a Range Rover universal joint. On the other side of that is the cut off splined bit of the Rover shaft, welded into the bottom of the Moggy Minor column. Easy.
The Godawful lumpy welds on the ends of the shafts were smoothed off with a sanding disc on the grinder, then I drilled through the joints & pinned them with 4mm engineers dowels, welded at either end.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 12, 2009, 01:24:36 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 13, 2009, 12:44:05 AM
Got all the various bits hooked up on the car today. The column's not hung inside the cab yet, but with it held in roughly the right place, we could turn the steering wheel & the front wheels actually turn. No grease in the steering box yet so it's a bit stiff, but it definitely works. The Moggy column now needs shortening by 6 inches but we need to splice in a section of collapsible column as well. Loony say VW Beetles use them & one of his mates should have a spare for us to pinch.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 13, 2009, 12:50:20 AM
Pops originally left the factory with a vinyl insert in the roof. It was quite common during the post war years when metal was scarce. A previous owner's already replaced it with a new steel panel, but it was totally flat -didn't follow the double curves of the roof. It was also just plonked on the outside rim of the body & welded where it touched, causing a ridge, which was covered with copious amounts of body filler. We stripped the filler off when we first got the car, but have decided the flat roof panel needs to come out & be replaced. Someone recently told me a Rover P6 roof has exactly the curves we need.
So Loony set to with the angle grinder.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 13, 2009, 12:51:07 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 13, 2009, 12:52:32 AM
The doors are still welded shut so with the roof panel removed we get our first proper look at the interior.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 13, 2009, 12:54:35 AM
It's actually roomier than you'd think. Plenty of leg room, just a bit tight on foot room, so good job it's an auto & only has 2 pedals. Now we can start working out the position of the seats, steering wheel, pedals, gearshift etc.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 13, 2009, 12:56:47 AM
Brummm, rumpitty, rumpitty, rumpitty, bruuummmm
-can't wait.  8)


Title: Re: Manky's Pop.
Post by: Mr_G on March 13, 2009, 01:23:22 AM
Didn't know that sun roofs had been invented back in the pop's day. Looking good matey, keep it up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2009, 12:09:17 AM
Another tiny step forward today.
The Moggy Minor steering column needed shortening by around 6 inches to fit the Pop cab. Although it's not needed for the Commercial SVA test, we thought it'd be wise to add a collapsible section to the column. So on my way home from work today, I took a detour to "Beetlelink" in Farnham, Surrey. They flogged me a second hand Beetle steering column for 15 quid, giving me a honeycombed collapsible bit.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2009, 12:20:35 AM
Unfortunately, the honeycomb section was too long, If I'd just cut the Moggy column, removed 6 inches, then welded in the collapsible bit, it would've ended longer than the original. So I had to cut the end from the section & shorten it, then splice it into the Moggy column. Very fiddly, using slugs inside each end, but it seems O.K. Not entirely sure the honeycomb bit is now long enough to be effective, but it's as long as I could make it. Column shortened from 30 inches long to 26.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2009, 08:27:49 PM
Hmm. We ran into our first real problem today & it's got us a bit stumped.
The whole steering train's now hooked up, from the steering wheel, through a Moggy Minor column & Rover intermediate shaft to a modified Pop steering box, then a drag link across under the engine to the opposite wheel. Fine -except it doesn't work.
It's almost as if the Pop steering box isn't man enough for the job. If we jack the front wheels off the ground everything's fine -turn the steering wheel & the wheels turn. Let it back down & it doesn't want to know. Feels as if the steering box is locked up. The front wheels are 15" Hillman Minx ones on skinny crossplies, so not much different in size to the original Pop ones. The big difference though is in the weight of the engine. A 3 1/2 litre Rover V8 must weigh a hell of a lot more than an old Ford sidevalve, even if the Rover is aluminium.
So how do we cure our lack of direction?
Would a longer arm on the steering box give more leverage? Should we be looking at power steering of some sort? Are we missing something very basic here?


Title: Re: Manky's Pop.
Post by: poprodder on March 18, 2009, 08:56:26 PM
any pics?

what angle have you on ya joint(s?)?





Title: Re: Manky's Pop.
Post by: cunningplan on March 18, 2009, 09:06:50 PM

Would a longer arm on the steering box give more leverage?

I would think that would make it worse


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 18, 2009, 09:23:41 PM
That's what we wondered CP.
Very hard to get photos with it all fitted in place. There are 2 universal joints, each running at less than the recommended max of 30 degrees. You can see the steering box further back in this thread. The drag link runs from the steering box, under the sump, to the far end of the cross link, where it attaches to a lug cast into the top of the ball joint. I wonder whether we'd get more leverage with it attached to an A arm on the back of the hub, as normal? At the moment it's pulling on the cross link, about 3 inches out from the back of the hub.
We haven't tried rolling the car forward while turning the wheel. Presumably that would be much easier. I know trad' rods tend to have basic, heavy steering, but we did expect to be able to turn the wheels while at a standstill.
I'll carry on knocking up a hanging bracket to mount the steering column to the underside of the dashboard while we figure this out. 


Title: Re: Manky's Pop.
Post by: poprodder on March 19, 2009, 12:12:35 AM
does this help,

(http://image.rodandcustommagazine.com/f/8554487/p88655_image_large.jpg)

(http://image.rodandcustommagazine.com/f/8554544/p88658_image_large.jpg)



Title: Re: Manky's Pop.
Post by: tony b on March 19, 2009, 10:47:29 AM
would a moggy steering box not work better


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 19, 2009, 05:16:22 PM
I'm not even sure Moggies have boxes Tony -are they rack & pinnion? I owned 3 of them so should know but can't remember. Not that I've got a spare Morris knocking about anyway.
Stupidly, I didn't even check the UJs were aligned when I slotted it all together. I'll check tomorrow, but can't see it would make any difference as everything works when the car's jacked up. I'll try & get some pics tomorrow.


Title: Re: Manky's Pop.
Post by: Mr_G on March 19, 2009, 06:45:25 PM
Never realised that stearing was so complicated!


Title: Re: Manky's Pop.
Post by: tony b on March 19, 2009, 06:51:59 PM
stupid me,moggiies dont have steering box,i ment robin ,sorry


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 19, 2009, 07:02:15 PM
We've got a spare Reliant rolling chassis, but reaching the steering box is a major operation. Don't want to chop up the body as it's in reasonable nick & we may be able to flog it to one of the Reliant owners club guys!


Title: Re: Manky's Pop.
Post by: BikerGran on March 20, 2009, 02:37:52 AM
Can you try towing it to see if it works on the move?  I was just thinking that maybe it's cos you are used to power steering - I can't get used to the fact that I can turn the steering on the new car when at a standstill cos I sure couldn't do it in the Maestro!  It's only since having power steering I've realised what a struggle I had to do a 3 point turn every morning!


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 20, 2009, 06:11:57 PM
We could just roll it out of the workshop door -that'd be enough momentum to check it Bobbi.
Had another look at it today & it really won't turn the wheels at all when it's at a standstill. At the moment I've got an old 8mm bolt holding the drag link to the end of the steering box arm. It's in a 10mm hole. With the car sat on level ground, the steering turns fine until that slack is taken up, then it stops dead -in other words, when it's under load the steering box can't physically push the wheels round.
I've had older cars without power steering in the past but don't really remember what they steered like. Taz says she's driven an old Toyota Hi Lux pick up truck that was just like that -couldn't turn the wheels unless it was rolling. I can't believe that's right though -or acceptable to SVA & MOT guys.
If there's a problem it has to be either a fault with the Pop steering box, in which case I'll pull apart the spare one I have & try that, or it's just not man enough to handle the extra weight of the V8 engine & we need to find a box from a heavier car that may have better gearing.
 


Title: Re: Manky's Pop.
Post by: Mr_G on March 20, 2009, 06:22:25 PM
Our works van is like that, its like a tank to try and move the stearing when its stopped, same as my old astra was.


Title: Re: Manky's Pop.
Post by: tony b on March 20, 2009, 07:26:58 PM
hi andy,i help out at a paintball site now and again.they have an ex army stalwart six wheel amphibious truck,if you can find out if they have steering boxes ,ill see if i can make one suddenly dissapere and unexplainedly land on your door step,maybe,if they are fitted to this truck it will definately be up to the job as the thing must weigh at least 5-6 tons


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 20, 2009, 07:48:49 PM
Cool! Cheers Tony!
Hmm, maybe I'm just used to wussy power steering.
I've just spoken to Chris from Pop Browns, suppliers of custom parts for Ford Pops. We went right through my steering set-up as best we could, with me waving my arms around trying to describe the movement over the phone.
I thought we'd turned the steering box through 90 degrees when we fitted it, but apparently we've mounted it the same way up as standard. We've also attached the drag link that connects the box to the wheels, to the same point as a standard Pop. Chris said Pop steering boxes are over engineered anyway so should handle the weight of a Rover motor O.K. So no obvious faults there then. He asked how heavy the wheels themselves are & whether we can physically push them round when the steering's disconnected. I said we can but need to put a knee against the tyre & give it a good shove. He thought that sounded quite heavy. We've got the weight of the engine mounted quite a long way forward compared to most V8 engined Pops, but then we've pushed the axle further forward too, so shouldn't be a problem. We've got the castor angle right, the spring shackle angle right, the steering box mounted in the right place, the connecting drag link right etc. No real faults. The only comment he made was that 10mm rose joints on the drag link sounded too small & we ought to upgrade to 12mm.
He suggested unbolting the engine & jacking it off the chassis a little, then trying the steering. If it works fine with just the weight of the chassis & only locks up when the full engine weight's on it, it's likely to be a buggered steering box. I'll try & hook up the spare to see if it works before stripping it down to shorten the column.
Hope this all makes sense -probably only if you own a Pop. Tried to take some piccies but it just looks a confusing jumble of linking rods.  


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 20, 2009, 07:50:39 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 20, 2009, 07:52:25 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 20, 2009, 07:54:09 PM
.


Title: Re: Manky's Pop.
Post by: poprodder on March 20, 2009, 08:04:06 PM
why not try posting this problem in tech on nsra?
you might get a slagging ::) or some good answers :o


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 20, 2009, 08:19:21 PM
 :) To be honest Chris, without wanting to "diss" the NSRA readership, every time I've posted questions on there I've been completely ignored, which is why I don't bother any more.
We'll keep plodding on. Since we've started this build, Loony & I have been waiting for a problem to crop up. Everything seems to have more or less fallen into place & we were overdue for a set-back. There's no grease in the steering box at the moment & the steering column's not attached to the dash yet. Not sure there's enough "meat" on the steering box pitman arm & the cross link mounting lug to change up to 12mm rose joints but if there is, I will. We'll keep working around the problem & see what happens.  


Title: Re: Manky's Pop.
Post by: brock on March 20, 2009, 09:34:43 PM
   looks and sounds fine, to be honest I wouldn't expect you to be able to get much movement without the whole system being finished, anchoring the column will make a huge difference as will greasing the box. 12mm Rose joints ! you'll be telling me the chassis is out of four by two next ! !
   If it is still too heavy for you, have a look at some of the electrically assisted modern stuff.

http://cgi.ebay.co.uk/CORSA-C-ELECTRIC-POWER-STEERING-COLUMN-KIT-CAR-ETC_W0QQitemZ230332232860QQcmdZViewItemQQptZUK_CarsParts_Vehicles_CarParts_SM?hash=item230332232860&_trksid=p3286.c0.m14&_trkparms=72%3A1683%7C66%3A2%7C65%3A12%7C39%3A1%7C240%3A1318

    for instance.


Title: Re: Manky's Pop.
Post by: tbone on March 20, 2009, 10:31:29 PM
Brocks post sounds convincing to me. Is the steering shaft being held in position by your feet! ?. How many monkies does it take, pulling on the wheel to get any hint of movement? What size is the steering wheel?


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 20, 2009, 11:11:00 PM
 :) That power column looks tempting. If there's a design flaw in our set-up somewhere though, won't forcing it with a power assisted thingy just risk breaking something? Would that require half the wiring loom from the donor car to operate it or could basic Monkey wiring do the job? No idea of the wheel diameter -14 inch maybe?
And yes, the column's currently supported by Loony's feet -he's starting to get cramp so I'd better get it properly fitted soon.


Title: Re: Manky's Pop.
Post by: tbone on March 20, 2009, 11:27:19 PM
The switchgear at the top of that column would presumably be disgarded? in which case the only wiring involved would be to the motor, with the ignition in the on position.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 20, 2009, 11:43:48 PM
Plastic switchgear? I don't think so -not in my hotrod.  8)


Title: Re: Manky's Pop.
Post by: ByzMax on March 21, 2009, 02:41:49 PM
Try jacking the front but just a little to take some of the weight off. Raise it an inch at a time and check. It may give you some idea of the cause.  ;)



Title: Re: Manky's Pop.
Post by: panthershaun on March 23, 2009, 10:37:35 AM
you could always build those arm muscles up mate  ;D :-*


Title: Re: Manky's Pop.
Post by: SteveRedd on March 23, 2009, 03:03:29 PM
yeah....get Taz to withdraw her favours for a couple of months  :P :P     ;D ;D ;D ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on March 23, 2009, 05:36:42 PM
 :o :o :o :-[ :-[ :-[ oooh Steve :-[ :-[ :-[ ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 23, 2009, 09:14:24 PM
Calm down gentlemen!
Just bought a Vauxhall Corsa electric power steering column from Ebay to experiment with. Ideally, I'd like to stick with very basic, 50s technology, but if it takes something hi-tech hooked up to the transverse spring/split wishbone jalopy front end to make it work, then so be it. Waiting with interest for the column to arrive in the post -wonder if I can graft my Moggy Minor steering wheel to it? I've also ordered a gizzmo from another Ebay seller that side steps the need for all the ECU/computer wizardry from the Corsa.


Title: Re: Manky's Pop.
Post by: TwistedPatience on March 23, 2009, 09:54:12 PM
"Electric Steering :o thingy wouldn't have had that in my day, bloody gimmicks, you'll be having more that 4 pistons next, an how's the old boiler supposed to power that then eh! where's the steam go then....bloody gimmicks" ....................."mutter mutter mutter" (all the way to the garage) ;D








I'll get me coat...an lock the door


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on March 23, 2009, 10:02:49 PM
"Electric Steering :o thingy wouldn't have had that in my day, bloody gimmicks, you'll be having more that 4 pistons next, an how's the old boiler supposed to power that then eh! where's the steam go then....bloody gimmicks" ....................."mutter mutter mutter" (all the way to the garage) ;D








I'll get me coat

PMSL ;D


Title: Re: Manky's Pop.
Post by: SteveRedd on March 23, 2009, 10:08:11 PM
keep us informed Andy, that sounds interesting


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 23, 2009, 10:39:48 PM
That's why we're building a pick-up Doc, so we can carry the coal in the back.  ;)
Could be a great solution to the problem -or a monumental failure, in which case I've just blown 70 quid on a power column I can't use. Guess I'd have to build something else around it.


Title: Re: Manky's Pop.
Post by: TwistedPatience on March 23, 2009, 10:55:22 PM
Trick Bonnet opener ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 23, 2009, 11:02:12 PM
Power can opener?


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on March 24, 2009, 09:30:13 AM
power turning bird feeder m8 !!


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2009, 09:35:00 AM
Now there's an idea!


Title: Re: Manky's Pop.
Post by: toad on March 24, 2009, 09:59:40 AM
another motor that use,s a power column is the newish shape fiat punto this ones switchable they call it city mode so doesnt need all the electrical gubbins that the vauxhall system uses its just a thought if the vauxhall one,s not up to the job. ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2009, 10:06:00 AM
Ain't technology wonderful! Got to try the spare Pop steering box first cos it might just be that the first one's knackered.
If it's still heavy though we'll move on to the power option. I bought the column from one guy on Ebay & a circuit board thingy from another that's designed to replicate all the signals from the Corsa's electrical system to enable us to just bolt it in -maybe.


Title: Re: Manky's Pop.
Post by: brock on March 24, 2009, 10:26:46 AM
"cos it might just be that the first one's knackered."

   or it might be because the column's not secured and the box 'aint greased


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2009, 11:06:26 AM
Yeah, that's what I told you Steve! And you're the one who sent me the link to the power column.
It'll be interesting to have a play with anyway.


Title: Re: Manky's Pop.
Post by: TwistedPatience on March 25, 2009, 01:46:53 PM
Quick update

Prop Flange, Done
Pin,Done
Gearknob, working on (and hope it is unmarked when I take the wrapper off)
Panhard Rod Boss, Done
Carb adaptor plate, To be done
Bearings,  Done


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 25, 2009, 04:02:31 PM
That's great Doc. Thank you.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2009, 09:03:39 PM
The Corsa column finally arrived via Ebay today.
I'm really hoping the spare Pop steering box will do the trick & we won't have to use this, cos it looks scarily complicated. I bought a circuit board from another Ebay seller, that's supposed to do away with the need for the Corsa's computer ECU gizzmos & run the column straight off the ignition power supply. We'll see.
Roughly the same length as the adapted Moggy Minor column, but much bulkier. I'm not even sure we've got the room to fit it. Again, we'll see. I won't get a chance to get over to Loony's workhop till next week now, so will keep you informed.


Title: Re: Manky's Pop.
Post by: cunningplan on April 06, 2009, 09:31:17 PM
The Corsa column finally arrived via Ebay today.
I'm really hoping the spare Pop steering box will do the trick & we won't have to use this, cos it looks scarily complicated. I bought a circuit board from another Ebay seller, that's supposed to do away with the need for the Corsa's computer ECU gizzmos & run the column straight off the ignition power supply. We'll see.
Roughly the same length as the adapted Moggy Minor column, but much bulkier. I'm not even sure we've got the room to fit it. Again, we'll see. I won't get a chance to get over to Loony's workhop till next week now, so will keep you informed.

saw one of these fitted to a rally car the other weekend, looked quite neat, it had a small black box fitted under the dash with only a couple of wires going to it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2009, 09:44:58 PM
Forgot to add the photo. Done now. Did it look like this Tony?


Title: Re: Manky's Pop.
Post by: Mr_G on April 06, 2009, 09:47:36 PM
Sweet, lazy steering is the way forward.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2009, 10:11:27 PM
 ;D Taz's Dodge Charger has power steering & that was built 40 years ago.
We've got very little leg/foot room in the Pop cab, so it may not fit, but we'll try.


Title: Re: Manky's Pop.
Post by: cunningplan on April 07, 2009, 07:17:17 AM
Forgot to add the photo. Done now. Did it look like this Tony?

Yes, looks like it came from the same car (Corsa) did not have time to ask how it worked as it was about 6.30 on the Sunday morning and we had about another 30 cars lined up to check.


Title: Re: Manky's Pop.
Post by: panthershaun on April 07, 2009, 07:54:35 AM
so have you ordered your 21 inch bling alloy's to go with the high tech steering then mate 8) 8) 8) ;) looks a little complicated and ugly. My Land Rover is a real pig to turn when stationary but no problem when rolling.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on April 07, 2009, 09:36:28 AM
that,s johnny 5's left leg  :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 07, 2009, 11:39:55 AM
That's exactly what I thought!
Shaun, I'm really hoping that's all it is -with a bit of forward motion I'm hoping it'll free up & be O.K. Just a bit unexpected that it really wouldn't turn at all when stationary. I used to own Moggy Minors a few years back, which obviously didn't have power steering. Don't remember them being quite so bad, but then they weren't running V8 motors.
I grabbed the Corsa column from Ebay while it was there, more as a Plan B than anything else. Like I said, really hoping I don't have to use it & we can stick with a traditional setup. There must be much heavier cars about without power assistance. If I had to go with the bionic arm I'd panel it in out of sight. 


Title: Re: Manky's Pop.
Post by: Firery Fred on April 07, 2009, 06:37:44 PM
Jumped into my mates Citroen C15 van to go to the shop and couldn't believe how heavy the steering was


Title: Re: Manky's Pop.
Post by: madron on April 07, 2009, 07:26:52 PM
manky just a thought kingpins avnt siezed while its been stood had this on a transit all it needed was some grease after warming up a bit


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 07, 2009, 10:15:40 PM
Everything works fine when the front end's jacked up off the ground Ron. It's just when the full weight of the engine/chassis is resting on it that the steering becomes so heavy. It may just be that we've only got the steering column propped in place in the cab & no grease in the steering box. Not been able to work on it this week, but will hit it again next week & get it properly bolted in, then see how it fares.
Never built a car from scratch like this before, so it's all new to us. 


Title: Re: Manky's Pop.
Post by: ByzMax on April 08, 2009, 09:42:58 PM
You will never get it to work if it's not bolted down. Sure it will get sorted  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 13, 2009, 08:07:02 PM
Picked up a possible set of rear lights for the Pop today at the Picket Piece Spring vehicle meet.
A tenner for the pair. 3 inch diameter lenses. I'd have to adapt them to take dual filament bulb holders though, for stop/tail lamps.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 15, 2009, 11:50:44 PM
I'm keeping all my digits firmly crossed, but we just might have sussed the stiff steering problem.
We're using a standard Ford Pop steering box, connected by 2 UJs to the steering column. That meant shortening the Pop steering column & adding a splined end section in place of the steering wheel to take the UJs. The column screws in & out of the box to turn the Pitman arm, which in turn steers the wheels.
Check the photos & you'll see there's a collar pressed onto the shaft. A tapered collar slips over the thread. the taper forms one side of the ball bearing race. Then the bearings go in, followed by a tapered nut, which forms the top of the bearing race, then a lock nut.
The tapered collar should be free to slip over the thead, but ours was solid. We assumed it was meant to be like that. That meant that as the steering column was turned, winding itself in & out of the box, the fixed collar was trying to drag the ball bearing assembly out of the end of the outer column sleeve, rather than the column passing through the bearings. It couldn't so the whole assembly locked up.
I know that makes no sense at all, unless you can see it in action, but trust me, it's a very simple cock up, maybe self inflicted by us, maybe not, that's easily fixed by rebuilding the old steering box with parts from the spare one I bought for a tenner at the NSRA swapmeet. Steering's still heavy when the car's stationary, but the wheels do turn.
Result! We hope.


Title: Re: Manky's Pop.
Post by: Mr_G on April 16, 2009, 05:55:57 PM
Glad you cracked your stearing issues matey. Hope everything else goes more smoothly for ya.


Title: Re: Manky's Pop.
Post by: Firery Fred on April 16, 2009, 06:40:50 PM
Hurrah!  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 16, 2009, 07:54:46 PM
I shall Hurrah when it's all fitted & working!
Loony's been eyeing up the power steering column for his long-term Volksrod project, so it won't go to waste. Really hope we can keep the Pop all fairly basic & retro though.


Title: Re: Manky's Pop.
Post by: Mr_G on April 16, 2009, 07:58:33 PM
Makes it more authentic I suppose and less to go wrong?!


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 17, 2009, 03:14:17 PM
Gear selector arrived safely today Andy. Are the washers meant to be that thick? I managed to get it to lock in park but not in reverse (or the other way round) will try some different washers and see if I can get it to work in all positions before I send it back.

Rod has been remade in ali as you requested, just need to finish the knob.

Will keep you posted pictures an all ASAP.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2009, 05:55:55 PM
That was quick. Ain't our postal system wonderful.  :) I didn't post it till 1.30 yesterday afternoon.
Loony & I shoved the washers under the base plate before I posted it to you, cos there didn't seem enough travel on the plunger to lift the selector pin over the ratchet -sorry folks, just talk amongst yourselves for a minute- so they were just a couple of old washers from the spares shelf. If you can make it all work without them, then that's fine. Wondered whether an aluminium operating rod would wear quickly, but I guess it'll be fine? 


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 17, 2009, 06:02:21 PM
Already thought of the wear thing,  will get some Stainless.


Title: Re: Manky's Pop.
Post by: poprodder on April 17, 2009, 06:16:56 PM
Already thought of the wear thing,  will get some Stainless.

stainless!! :o  not very retro, what you need is some rusty old steel ;D


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 17, 2009, 06:23:09 PM
I agree Poprodder, I did suggest brass but Manky is allergic to brass I think ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2009, 07:13:06 PM
Twisted's slowly stockpiling the entire country's brass reserves. Where there's brass there's muck, or something like that.
No other brass parts in the Pop, so it would kinda clash with the black & red colour scheme I think. The stainless rod is the bit operated by the button on top of the gearknob, that locks out the gears in the Rover auto box. So it's hidden inside the chrome gearstick.
The base plate of the gear selector's slightly twisted, making gear changing a little sticky. We're worried it'll break if we try to straighten it. Don't suppose anyone's got a spare Rover P6 gearbox selector gate?


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 17, 2009, 07:18:46 PM
Slightly twisted is a bit of an understatement :'(


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 17, 2009, 07:19:13 PM
Look at the top edge it's curved.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2009, 07:49:46 PM
Makes you wonder what happened to it doesn't it. Fortunately the top only holds the plastic cover with the gear positions marked on it, which I hope to replace with a CNC machined aluminium plate. The whole assembly's twisted but as long as the gearstick still postively selects each gear I guess it will work.


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 18, 2009, 06:48:59 AM
The top plate also holds the position of the gear stick which is out of line that's why to select all the gears the front bolt has to be loosened or tightened depending on what gear you want.

To be honest it's not much use as it is, will see if it can be machined from a solid lump of ali with the gates inserted into slots as per the original.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 18, 2009, 11:19:35 PM
*sigh*. One step forward, yet another back.
O.K Doc, thank you. I'll leave it in your capable hands.  ;)


Title: Re: Manky's Pop.
Post by: panthershaun on April 19, 2009, 09:22:37 AM
CNC machined aluminium plate.

Stainless :o cnc :o :o watch out American Rodder (RIP) Mankys after your crown :D :D :D :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2009, 09:50:15 AM
Actually Shaun, I've been thinking of asking Clive, our resident painty person, to paint the gear positions in red on a black powder coated steel cover plate -more in keeping with the colour scheme & retro look of the rest of the build -& possibly marginally cheaper.
How's your build going?


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 19, 2009, 06:31:07 PM
Managed to get the top plate clamped down straight on your gear shift gate will leave it that way for a while see if it helps at all, if not back to the drawing board. ;D


Title: Re: Manky's Pop.
Post by: panthershaun on April 19, 2009, 07:45:59 PM
bloody slow mate ::) ::) ::) keep getting side tracked by other things and of course that dreaded work thing >:( >:(


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 20, 2009, 03:55:21 AM
Thanks Doc.  ;) The shifter mechanism will be bolted directly to the top of the gearbox, so will hopefully be clamped down good & tight. May be able to make the selector gate plate to fit over the mechanism & also bolt to the g/box, to further hold it all in the right place.
Yeah, I know what you mean Shaun. I need at least another 24 hours in every day -& about a week's more sleep. Permanently knackered but never seem to get anything achieved.


Title: Re: Manky's Pop.
Post by: panthershaun on April 20, 2009, 05:33:33 AM
curse of the postal classes mate, when I work lates I'm not so tired but don't have any time to myself and earlies means I have free time but to bloody knackered to do much ::) ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 20, 2009, 09:02:37 PM
I've had 23 years of the early shift & still not used to it.  :(
Visited my big brother Brock a couple of days ago & he was kind enough to interrupt his drag car building schedule to TIG weld a couple of odds & ends for me. Doc, (Twisted Patience), machined me a mounting boss to attach the panhard rod to the Pop axle. Brock welded it in place so today we were able to bolt it up. Loony tested it by bouncing up & down on the chassis -all seemed well, with the various linkages moving freely without fouling on each other. result.
Yeah, I know the sticky-out tubey bits are rusty. They're the radiator/ grille shell mounts & it's only surface rust. It'll eventually be blasted off & powder-coated.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 20, 2009, 09:06:04 PM
MR B also cut the prop shaft down to size with his chop saw, leaving the cut end nice & square & true to take the universal joint machined down by Doc. I had a quick check to make sure it fitted. It'll run through the cab at the same height as the seat bases. The rubber "donut" joint between the 2 prop sections will be mounted to the underside of the cross member at the rear of the cab.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 20, 2009, 09:15:09 PM
Flap's trike's in to have a set of rear mudguards made up.
Although they're not needed for the MOT, (last year the examiner actually rang the Ministry for guidance & was told if they're not fitted they can't be tested & therefore can't fail), they are a construction & use requirement so should be fitted for road use. Flap's supposed to be joining us at the weekend for the MonkeyWorld run down to Dorset & needs an MOT before then. Personally I don't think we've got time to get the guards sorted & powder-coated so he ought to be concentrating on checking everything's working & MOTing it, then doing the guards at his leisure. We'll see.
An Ebay bidder turned up at the yard today to check over the Hillman Minx that's currently up for grabs. Apparently he looked across at the Pop & said What a shame they've cut it up. Miserable old git. Hope he loses in the auction now.


Title: Re: Manky's Pop.
Post by: Mr_G on April 21, 2009, 06:50:03 PM
People like that obviously don't appreciate fine art!


Title: Re: Manky's Pop.
Post by: TwistedPatience on April 23, 2009, 07:01:51 PM
As promised two photo's of the Gearshift.
Managed to straighten the top plate by clamping in the vice for almost a week, seems to have done the job.

New stainless shaft and button turned and polished, just got to complete the Knob it's self, it's nearly done.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 23, 2009, 10:36:44 PM
Ain't it nice to have good mates.
Many, many thanks Doc.  ;)
Just a quick update -I took the iffy steering box, plus the spare I bought at the NSRA swapmeet, over to my brother Brock's workshop last week & we put together one good one from the two. Nothing obviously wrong with the first one, except it was bone dry & full of swarf, probably from me shortening it down. Like most mishaps on this build, it was probably self-inflicted but hey, I've never built a car before & it's a steep learning curve as they say.
No photos as not a lot to see, but I fitted the new box this afternoon, plus a couple of bronze bushes in either end of the drag link to take out the free play, (thanks for those too Doc). The steering column's still not fixed inside the car, but even balancing it on my knees & turning the wheel, we had movement at the wheels. Looks like we've sussed it.
Anyone want to buy a power steering column?  ;D
I've also been to Newbury in Berkshire this afternoon & collected the aluminium radiator from the welding shop where they've repositioned the inlet & outlet spigots to suit our set-up.
Getting there -very slowly.  :)


Title: Re: Manky's Pop.
Post by: panthershaun on April 25, 2009, 04:18:47 PM
 :'( :'( :'( far better than me then  :'( :'( :'( :'( managed 5 mins up the barn today but had to rescue some of my junk I mean projects from a mates barn as it looks as if he may be evicted and all the contents sold to pay his arrears in rent ::) ::) ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 25, 2009, 04:26:53 PM
Really? Would that be the gentleman with the large collection of interesting machinery? If so, save several for me please.


Title: Re: Manky's Pop.
Post by: panthershaun on April 25, 2009, 04:29:47 PM
one and the same  :'( :'( :'( breaks my heart to see it all just sitting there but I don't have any free cash at the moment to buy him out ::) ::) :'( :'( :'(


Title: Re: Manky's Pop.
Post by: tazet on April 25, 2009, 05:42:21 PM
Free cash ha, you'd need a loan to buy that lot out. Is he selling privatley in bits or as a job lot?


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 25, 2009, 06:44:21 PM
Seriously Shaun, might be interested in a future project or 6 if they were going dirt cheap.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on April 25, 2009, 07:23:57 PM
Now there's a man who plans on living forever........ ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on April 25, 2009, 09:03:24 PM
Seriously Shaun, might be interested in a future project or 6 if they were going dirt cheap.

I'll let you know what happens, those rigid/girder Enfields would make great Bobbers ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 25, 2009, 10:16:14 PM
Just what I had in mind.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 01, 2009, 07:13:06 PM
Been messing about with odds & ends on the Pop for the last week, without actually making any discernable progress at all. I was out in the shed till gone midnight last night, knocking up a very basic but very substantial column drop for the steering -that's a bracket to attach the steering column to the framework under the dashboard. A 2 piece clamp around the column itself, bolting up from underneath into M8 captive nuts, welded to 2 lengths of 3/4" ERW tube, with 1/4" mounting tabs slotted into the ends, which bolt to matching tabs on the bulkhead frame. Might mount some warning lights in the centre panel, or maybe drill some holes in it. Some ugly welds on the top tabs cos I was welding in the shadows while balancing the wheel in place on my knees, but they'll clean back O.K.
  


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 01, 2009, 07:21:51 PM
Everything's a bit tight but it should work -about a hand's width between the wheel & the driver's door. The intermediate shaft between the Moggy Minor column & the Pop steering box runs within 10mm or so of the starter motor, so I hope the engine doesn't rock about too much on it's mounts. I'm using Pop Brown's nylon bush mounts, rather than the original rubbers, so with luck it'll all be O.K
Here you can see the short section of VW collapsible column I welded in at the base of the Moggy shaft.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 01, 2009, 07:32:06 PM
I've got a large rose joint which I'm hoping to use to support the bottom end of the column.
When Brock & I rebuilt the steering box we adjusted the free play in the shaft until it felt right. Now it's attached to the column though, there's about an eigth of a turn of freeplay in the steering. Hopefully tweaking the adjustment on the box will reduce that.
None of the universal joints are bolted up tight yet & I noticed as I left Loony's workshop this evening that at least one of them is turning on the splines, which would explain some of the free play. At least with the steering wheel now set in position, we can adjust the rest around it. 
Oh, the framework on the floor in front of the car is the seat runner from a 206 Peugeot, being scrapped tomorrow. Hoping to mount the driver's seat on it.


Title: Re: Manky's Pop.
Post by: Mr_G on May 01, 2009, 08:14:13 PM
Looking good Andy, I wish that all Peugot 206's were being scrapped tomorrow!


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 01, 2009, 08:21:08 PM
 :D Only one seat in the hatchback, but if the other one turns up I'll pinch the frame from that too. As well as forward & backward adjustment they're also adjustable up & down, which means Taz, Loony & I can all drive it in a modicum of comfort.


Title: Re: Manky's Pop.
Post by: tbone on May 01, 2009, 08:52:06 PM
but not at the same time!  ;D


Title: Re: Manky's Pop.
Post by: BikerGran on May 01, 2009, 09:42:07 PM
Anything's possible!


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 01, 2009, 10:43:20 PM
 ;D It's destined to be a ...snug, fit in the cab I think.


Title: Re: Manky's Pop.
Post by: panthershaun on May 02, 2009, 07:58:27 PM
looking good dude, far far ahead of me now ::) ::) ::) :'(


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 02, 2009, 08:28:11 PM
See you in the dirt at next year's Hotrod Hayride then Shaun.  ;)
Welcome back from your hols by the way.


Title: Re: Manky's Pop.
Post by: panthershaun on May 04, 2009, 08:08:51 AM
still aiming for this year mate  :o but it will be in primer with just enough finishing touches to get her legal ;D


Title: Re: Manky's Pop.
Post by: spanners on May 18, 2009, 06:21:12 PM
andy you runnin rover v8 in the pop?  i,m riddin out some stuff overthe next few weeks  v8 bits are lying about  inlet manifold/carbs,,electroni dizzy,s  earl coupe steering boxe,s etc,etc give us a wanted list and i,ll look

also a j reg l/r disco 200tdi for breaking good engine  with nearly new g/box


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 18, 2009, 07:09:48 PM
Hiya,
yup, Rover 3 1/2. Bought it as a running engine so hoping to at least get it built & registered before having to rebuild it. Got an auto box cos there just isn't enough room in the footwell for a clutch pedal!
I'm using a modified Pop steering box, but others here might be interested if you've got spare Rover ones.
Called at the workshop on my way home today to do some measuring up of various parts. Ended up unbolting the twin SU carb manifold & bolting on the replacement -a Holley 4 barrel on a manifold that came from a Buick, though I'm not sure whether it's a gennie Buick job or aftermarket.
Fitted fine but looks like I need an angled base plate to level the carb up -found a guy who can make them when I was at the NSRA swapmeet a couple of months ago.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 18, 2009, 07:12:12 PM
Not sure what's been going on in the inlets, but a couple of them were bunged up with a bright pink, soapy substance. Doesn't seem to have done any damage, but will need cleaning out.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 18, 2009, 07:18:51 PM
I was concerned the new carb would sit much higher than the SUs, which would mean cutting a hole in the bonnet panels. Fortunately it actually sits lower, so even once it's levelled up, we can keep everything inside the lines of the bodywork.


Title: Re: Manky's Pop.
Post by: spanners on May 18, 2009, 07:20:59 PM
that pinky stuff is in the water ports  it looks like a reaction with the type of antifreeze used iv,e seen it before on rover alumium and other makes when you fit the manifold for good  change the valley gasket and beshure to renew the rubbers at each end a known source of oil leaks   the first time you try to start her up leave the breather traps off or enshure the crankcase can breath freely  then if you get a miss/backfire it wont split the valley gasket


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 18, 2009, 07:23:05 PM
That's useful info Mike. Thanks.


Title: Re: Manky's Pop.
Post by: Mr_G on May 18, 2009, 09:52:59 PM
S'comin together nicely sir.


Title: Re: Manky's Pop.
Post by: spanners on May 18, 2009, 10:35:12 PM
if you ever do split a valley gasket through a backfire or simalar DONTput youre finger/s under the manifold they split/tear that sharp it will take finger ends off


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 21, 2009, 05:14:16 PM
Ordered a new thermostat, radiator cap & the end rubbers from "Real Steel". They no longer sell tin valley gaskets & recommend using a thick composite one, so I've ordered that as well.
Today Taz & I have been up to Luton in Bedfordshire to drop the Pop propshaft off at "Reco-Prop". I wanted them to weld the UJs on either end of our shortened tubes & balance it, but they've recommended making a new, 3 inch diameter, single piece prop & re-using our UJs on it. Just have to check a one piece tube won't foul the chassis cross members & re-check the overall length before they start on it.


Title: Re: Manky's Pop.
Post by: spanners on May 21, 2009, 07:53:28 PM
might have some valley gaskets  somewhere ,,,,,,,,,,,,,,,i know of one in the shed its new but bin hangin on the wall along time but i,ll look at it


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 21, 2009, 10:41:01 PM
Thanks Mick, but I've ordered the composite one -Real Steel reckon it's better than the original.


Title: Re: Manky's Pop.
Post by: panthershaun on May 22, 2009, 07:26:11 AM
met another  ::) pop pickup builder last night, mind you his is a big bucks build ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 22, 2009, 03:06:15 PM
Really? Tell me more matey.


Title: Re: Manky's Pop.
Post by: poprodder on May 23, 2009, 11:14:39 PM
i've a composite valley gasket on my rv8 off ebay for around a tenner with end seals.
just see it in this pic.

(http://media2.dropshots.com/photos/64941/20061118/163652.jpg)

good progress by the way.

cheers chris.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 24, 2009, 07:58:05 AM
Hi Chris. Not entirely sure where the rubbers fit -where should I be looking for them?


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 24, 2009, 08:34:59 AM
Had a delivery from europaspares.com yesterday -lookit, lookit! Ooh, a shiny new oil cooler!
We're using a Borg Warner automatic gearbox on the Pop. Not entirely sure what goes on inside autos -never owned one before. I'm assuming it uses hydraulic pressure to provide the drive? Anyway, the transmission fluid gets hot so we need an oil cooler. Europa recommend a 13 row unit for large road engines, so that's what we have here.
We played about with various mounting options -under the radiator, alongside the gearbox under the floor etc, before plumping for inside the front grille in front of the top of the rad. It'll stand off the rad by a couple of inches as the top of the front grille is twice as deep as the bottom, so should get plenty of air flow around it without heat transfer from rad to cooler or vice versa. Ideally we'd mount it off the rad itself on aluminium brackets -I've got no intention of actually racing this car, but we keep saying it looks very sporty with the nose bodywork removed. Would be nice if it could be run like that with everything self contained within the engine bay. In the end though we decided it will be much easier to mount it from the tubular framework around the inside of the grille shell.
The radiator & carb are only propped in place here by the way, which is why they all look slightly out of line.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 24, 2009, 08:43:43 AM
So my homewok for this weekend is to knock up some angled tabs to mount it with. Next job will be to look at moving the alternator. No real need to, but we reckon it'd look much tidier bottom left of the engine bay, rather than top right as it is at the moment. That Holley carb doesn't look as crazy as the pair of SUs sticking out the top of the motor, but is much tidier. Once all the ancillaries are in place it'll get quite busy in there, so I think it'll work out better.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 24, 2009, 09:04:46 AM
I also bought a pair of rear indicators from Europa -they specialise in kit car parts

https://www.europaspares.com/

Glass lenses, about 3" diameter, with Made in England stamped on them, (we're trying to use as much British stuff as possible on the build, rather than just copying the Yanks). I thought they'd match the rear lights I bought from an autojumble. Decided they'd look better with a matching pair of red stop/tail lamps though, so the jumble ones will go in the spares box. I'll mount them in the corners of the rear valance panel, (under the pick-up tail gate). That'll keep them within the 400mm from the outside edge of the vehicle measurement, that seems to be standard on vehicle regs. I'm now thinking of swapping the headlight sidelight bulbs for amber ones, to give indicators within the headlamps, as early Beetle ones have, & adding small cowl lamps for the sidelights, up by the top door hinges. Got to check with kev Rooney, who was involved with the drafting of the SVA regs, to make sure in-headlight indicators are O.K


Title: Re: Manky's Pop.
Post by: poprodder on May 24, 2009, 04:16:07 PM
the end seals go at either end, held in by a curved piece of steel with a bolt through(i think from memory!!! ::)  )

is the oil cooler sold as a trans cooler or engine?

different size fittings.

cheers chris.

ps. i'm keeping to 4 speed manual at the moment. as autos are new to me!!! :-\


Title: Re: Manky's Pop.
Post by: poprodder on May 24, 2009, 04:20:22 PM
re lights.

are side repeaters needed? as kev fitted them to his a-pick up which recently passed the test, he might have fitted them just to stick a finger up to the anti sva etc squad  :D to show that it can look like a rod and not frankenstiens monster!!! ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 24, 2009, 08:41:06 PM
Hiya,
the commercial SVA, which we're going for, as did Keith, doesn't check positioning for lights at all. It's a really, really basic test, intended I think for commercial coach builders who register their vehicles before the bodies are added, so most of the car SVA points don't apply. The commercial test gives rod builders a loophole to side-step the car test, but is being closed in 2011 -so expect to see lots more rodded pick-ups in the next year or so. Obviously we don't want to upset the powers that be by taking the mickey too much, so Keith is very keen no-one messes things up for the rest of us before 2011. Side repeaters are one of the few things that are necessary. I'm planning on mounting mine in the side vent flaps, just ahead of the doors.
It's a trans cooler, but they come in a choice of fittings. I went for 1/2" BSP.


Title: Re: Manky's Pop.
Post by: poprodder on May 24, 2009, 09:06:25 PM
cheers.
i asked about trans coolers on that other forum and got these answers.

http://www.nsra.org.uk/newforum/showthread.php?t=19816


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 25, 2009, 01:39:50 AM
Looks like we're on the right track then, which is nice to know.


Title: Re: Manky's Pop.
Post by: panthershaun on May 25, 2009, 07:29:56 PM
Hiya,
the commercial SVA, which we're going for, as did Keith,
Whose Keith ??? ??? ??? ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 25, 2009, 08:36:54 PM
Woops! Kev, not Keith -well I did type that at half past 2 in the morning.  :)


Title: Re: Manky's Pop.
Post by: panthershaun on May 25, 2009, 09:22:32 PM
he he he I knew who you meant, just being a little bugger  ;D ;D ;D ;D ;) :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 25, 2009, 09:30:41 PM
You do it so well.  :P


Title: Re: Manky's Pop.
Post by: panthershaun on May 25, 2009, 09:32:31 PM
I do hope so ;D ;D ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 26, 2009, 09:21:25 PM
I made up the right angled mounting tabs for the cooler over the weekend & took them over to Loony's place today. We welded them to the framework around the inside of the rad grille. The cooler bolts to the brackets with some rubber washers to cushion it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 26, 2009, 09:23:42 PM
With the grille back in place there's about 3" of clearance between the cooler & the radiator, so plenty of airflow around both components. Yeah, the rad & grille are still out of line. They're on slotted mounts & will be squared up later. Job done.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 26, 2009, 09:31:33 PM
Another longterm project at Loony's. Doug's split screen bus. He's working on replacing the floor & sills at the moment.


Title: Re: Manky's Pop.
Post by: poprodder on May 27, 2009, 04:50:47 PM
is that splitty as bad as it looks :o

would it of been easier to mount cooler lower down?
making routing of pipes easier? just a thought.


Title: Re: Manky's Pop.
Post by: poprodder on May 27, 2009, 10:04:52 PM
(http://www.rodsnsods.co.uk/forum/attachment.php?attachmentid=1520&d=1243379720)

http://www.rodsnsods.co.uk/forum/showthread.php?t=1675


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 28, 2009, 03:25:26 PM
Can't view the images on the forum without becoming a member, which I haven't gotten around to yet.
Below the radiator was our first thought, but the Pop grille tapers & the cooler would've poked out either side at the bottom. Also would've made it more vulnerable to cr*p flung up off the road, plus the pipes would've been dangerously close to the road, even with 90 degree elbows. The pipes will run down either side of the inside of the grille then tuck under the front chassis member to hook up with the gearbox.


Title: Re: Manky's Pop.
Post by: poprodder on May 29, 2009, 04:49:32 PM
pictures got nothing to do with oil coolers!!!
just thought it looked the bo****ks. ;D ;D ;D 8)

(http://media7.dropshots.com/photos/585570/20090529/094621.jpg)


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 08:51:42 PM
Wow!
All that on standard Pop chassis rails. That's mad. So short -the handling should be, erm, interesting!


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:04:08 PM
Exchanged a couple of emails with Kev Rooney, the SVA guru today. I'd hoped to get round the problem of finding decent looking period indicators by fitting trafficators -those orangepop-up flag thingies. Thought they'd be quite cool & could flash like normal indicators. Kev says they have to visible from 45 degrees from the front of the vehicle though, so for example, if you stand in front of the left front wheel, you should be able to see the right front indicator, which counts them out. I always think motorcycle flashers on rods look a bit naff & a bit of a cop out, so need something suitably old fashioned, but clearly visible. I thought maybe small cowl lights mounted up by the door hinges, but Loony thinks they'd spoil the lines of the body. Down by the bottom of the grille shell would be hidden by the front wheels when viewed from 45 degrees. So maybe on top of the front mudguards? Not sure yet.
We're trying to work from front to back, getting everything sorted before moving further back.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:13:03 PM
Taz & I nipped over to Mitcham, on the outskirts of London town this evening, to Tino's Rod & Custom. He's working on a stainless exhaust manifold for my trike & was also going to make a set of stainless headers for the Pop. Hasn't had time to look at them yet though, so I've taken them back to get done elsewhere. He did however give me a roof panel for the Pop. It was cut from a scrap Rover P6 & hopefully has more or less the right curves to suit the Pop roof line. Here Tino's plasma cutting it in half to fit in our little Fiesta. Being a pick-up, we only need half the roof length for the Pop. Just hope we cut it in the right place.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:15:19 PM
This 70s T bucket has just been fitted with a new exhaust too.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:16:24 PM
Nitrous injected Cortina engine.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:17:28 PM
Tino's own motor.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:18:18 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:20:21 PM
A few other projects scattered about the yard.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:21:16 PM
Cossie engined Corsair.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:22:24 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:23:49 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:24:48 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:25:46 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:26:37 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:27:46 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:28:33 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 29, 2009, 10:29:40 PM
.


Title: Re: Manky's Pop.
Post by: spanners on May 29, 2009, 10:50:33 PM
corrr i,ll have the wrecker  and the corsair please  but i,m not bothered about the cozzie lump   
  i just love corsairs we used to run them  i just wish we,de kept the one,s we had  :( :( :(


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 30, 2009, 02:23:02 AM
The truck's gorgeous ain't it. Still in it's original paint too. Great to know there's still yards like this about.


Title: Re: Manky's Pop.
Post by: TwistedPatience on May 30, 2009, 05:15:28 AM
Can I have the grey Zephyr please


Title: Re: Manky's Pop.
Post by: spanners on May 30, 2009, 07:01:28 AM
The truck's gorgeous ain't it. Still in it's original paint too. Great to know there's still yards like this about.

ohh sod it i,ll push the boat out and relocate

can i have the whole yard and contents please  ;D ;D ;D ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on May 30, 2009, 11:16:50 AM

what is the blue/white roof one with GB + AA badge?


Title: Re: Manky's Pop.
Post by: spanners on May 30, 2009, 11:40:38 AM

what is the blue/white roof one with GB + AA badge?

 to be honest i,m not sure    could be early  ,volvo, ???????


Title: Re: Manky's Pop.
Post by: trev on May 30, 2009, 01:25:43 PM
can i have the grey austin a70,my dad had one of them for years,what a great place.


Title: Re: Manky's Pop.
Post by: panthershaun on May 30, 2009, 02:45:43 PM

what is the blue/white roof one with GB + AA badge?

I think its a Hillman California, I may be incorrect :P :P


Title: Re: Manky's Pop.
Post by: panthershaun on May 30, 2009, 02:46:45 PM
pictures got nothing to do with oil coolers!!!
just thought it looked the bo****ks. ;D ;D ;D 8)

(http://media7.dropshots.com/photos/585570/20090529/094621.jpg)
you know I told you I was talking to a chap building a blown hemi Pop pickup, thats the one ;D ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on May 30, 2009, 03:12:13 PM

what is the blue/white roof one with GB + AA badge?
#
here you go guy's Hillman Minx California


Title: Re: Manky's Pop.
Post by: spanners on May 30, 2009, 03:45:55 PM
can i have the grey austin a70,my dad had one of them for years,what a great place.

do you really want one or something very simaler??

how about a austin devon  been in a shed abuot 10/15 years  she,s a little rough  but perfectly restoreable

only came outside a few months ago  coz the shed was rebuilt larger to serve another purpose  not shure of price  but very,,very cheap to good home

it belongs to an old friend,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,actually the farther of the lass i,m with at the mo


  so if youre interested or know of someone who is  i can get her for you or arrange for you to get her

  i dont want to see her left standing much longer


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 30, 2009, 05:02:03 PM
Dropped the roof panel off at Loony's workshop after work this afternoon.
For those who've forgotten since yesterday, this was given to me for nuffink by Tino, the guy who's knocking up an exhaust manifold for my trike. He's got a workshop in Mitcham, Surrey, on the outskirts of London, & a yard behind it crammed full of interesting motors. The roof was plasma cut from a Rover P6, (the 1970s, sloping roofed, 4 door saloons, often used as Police patrol cars, if you're old enough to remember them -I am  :( ). Tino's into V8 Ford Pilots, which are a slightly bigger, 4 door version of my Pop, & reckons these panels fit them a treat, to fill in the hole left by the original vinyl insert.
To fit it in the back of my little Fiesta hatchback we had to cut it in half, hoping the 2 bits would be wide enough to bridge the open roof of my pick-up. Here it is, laid in place. Seems to work. Once it's trimmed back to size it should fit nicely & follow the Pop's original roof curviture -unlike the totally flat panel that was fitted when I bought the car. This is actually the rear half of the Rover roof as the curves matched better. The front half still has the aerial attached to it! Of course, we can't weld this in place yet as the doors are still tacked shut & we need to climb in & out of the roof to work on the interior! 


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 30, 2009, 05:04:26 PM
.


Title: Re: Manky's Pop.
Post by: panthershaun on May 30, 2009, 05:31:31 PM
can I have the other half if it isn't being used  :-* :-* :-* :-* :-* :-* :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 30, 2009, 08:24:57 PM
Knew you'd ask that Shaun! Course you can, but I'll have to fold it up quite small to get it in the post to you.


Title: Re: Manky's Pop.
Post by: Simple Simon on May 31, 2009, 09:34:01 AM
You could always fold it in a couple of places in just the right way and send it air mail ;D


Title: Re: Manky's Pop.
Post by: panthershaun on May 31, 2009, 09:37:59 AM
I'll try and make a trip down to you soon, would like to catch up on the progress of the Pop and trike(s) in person anyway ;D


Title: Re: Manky's Pop.
Post by: Mr_G on May 31, 2009, 05:43:46 PM
So when this build is done will it be registered on a Q plate? Same question about yours and Taz's trikes. Looking better and better all the time Mr M.


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 31, 2009, 07:13:37 PM
G, yeah, all 3 vehicles will be Q plated. The trikes will go through the MSVA registration process, well the new BIVA equivalent anyway. The Pop will go through the commercial SVA. So all will effectively be brand new vehicles.
Shaun, you know you're always welcome to drop by, but Taz & I will probably be down your way on the 21st June for the Invicta Roadsters' Father's Day Chicken Run. 


Title: Re: Manky's Pop.
Post by: panthershaun on May 31, 2009, 09:45:00 PM
but I'll be in France  ::) ::) ::) ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 31, 2009, 10:40:12 PM
Well we ain't delivering your roof panel to France!
I'll leave it at Loony's workshop, just in case you call by when I'm not around.


Title: Re: Manky's Pop.
Post by: panthershaun on June 02, 2009, 09:22:55 PM
Mr Manky, I have found you a pedal assembly, I will let you know when I have got it ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 03, 2009, 03:24:18 PM
Thank you Shaunus -anyone remember Shaunus the woodland gnome? (creepy black & white kids puppets show -still freaks me out). Had a look at the Pop footwell today -we need pedals that come up through the floor, so we can mount the brake cylinders alongside the chassis rail with the pedal pivotted off a chassis mount too. Would Citroen pedals do that?


Title: Re: Manky's Pop.
Post by: panthershaun on June 04, 2009, 07:58:43 AM
no pleasing some people  ::) ::) I don't think so mate, but I do have the original Pop pedals for the clutch and brake that pivot from the floor if any good???


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 04, 2009, 08:07:39 AM
Ahh, no idea what happened to mine, so yeah, they might be very useful. Messing about with a few odds & ends on the front end at the moment, then pedals will be the next job. Are you coming up this way before your hols or can we arrange to collect from your place when we come down for the Chicken Run on the 21st? Swap 'em for a roof panel?  ;)


Title: Re: Manky's Pop.
Post by: panthershaun on June 04, 2009, 09:26:13 AM
Ahh, no idea what happened to mine,
;) ;) :-* don't think I can make it before france, we have a mag arriving soon and I have to mail it out for the subs guy's and gals  ;D
I could mail you the Pop ones, haven't got my hands on the 2cv one yet.

Swaps are always good ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 04, 2009, 10:08:17 AM
We've got a pair of Rover ones & a pair of Reliant ones, but a third option would be handy. Let me know the postage then please matey. 


Title: Re: Manky's Pop.
Post by: spanners on June 04, 2009, 11:43:28 AM
ther,s some 1600e one,s in the shed


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 04, 2009, 11:47:53 AM
Blimey! We'll be awash with pedals!
All we need is a basic pair, (throttle & brake), that come up through the floor & are reasonably small -very short of space in the footwell. The brake one will be linked by a rod to 2 master cylinders, linked together by a cross bar, mounted under the floor. That'll give us the dual circuit brakes we need for the SVA test. The throttle will be a cable hooked up to the Holley carb.


Title: Re: Manky's Pop.
Post by: spanners on June 04, 2009, 11:55:10 AM
i,ll look em out complete with cast ally bracket to take two master cyl,s   would have had one for brake and one for clutch bothe same size and next to each other just chop out one pedal even the pivot shaft spacing and fit the balance bar job done

  i did the same years ago when a fitted a rover v8 auto to a 1600e


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 04, 2009, 12:38:53 PM
You may have just saved us some work there!


Title: Re: Manky's Pop.
Post by: panthershaun on June 04, 2009, 06:26:54 PM
postage gratis mate ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 04, 2009, 06:43:02 PM
No idea which set will work out best Shaun, but I'll reimburse the postage & return the pedals if we don't use 'em. Thanks.


Title: Re: Manky's Pop.
Post by: panthershaun on June 04, 2009, 09:51:49 PM
no you won't :P :P you may return the peddles but the postage is free old chap ;D ;D ;D :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 04, 2009, 09:56:53 PM
Oh, O.K then! Thanks Shaun.  :-*


Title: Re: Manky's Pop.
Post by: panthershaun on June 05, 2009, 08:04:11 AM
pleasure is all mine :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 05, 2009, 09:39:14 AM
He must be after something, but I'm not sure what!


Title: Re: Manky's Pop.
Post by: panthershaun on June 05, 2009, 09:40:56 AM
one roof panel ;) ;) ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 05, 2009, 09:49:36 AM
 ;D Only scrap metal to me matey, left over from my own, so you're welcome to it. Hope it's long enough to span the gap on your roof as my half just fits. Tis free anyway.
Looks like I'll be doing the Invicta Roadsters Chicken Run on the 21st, so can swing round your way & leave it under whatever vehicle's parked on your drive while you're on holiday. To save the postage, you could leave the pedals there for me to collect at the same time. A bit of a plan -most unlike me.  :P


Title: Re: Manky's Pop.
Post by: TwistedPatience on June 05, 2009, 02:15:21 PM
Just getting your gear shift sorted ready for posting and took a few photo's for your online scrapbook.


Title: Re: Manky's Pop.
Post by: TwistedPatience on June 05, 2009, 02:17:35 PM
.


Title: Re: Manky's Pop.
Post by: TwistedPatience on June 05, 2009, 02:18:08 PM
Waiting for the glue to dry before assembly and boxing up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 05, 2009, 05:22:33 PM
That's fantastic Doc. Thank you so much for that. I don't expect freebies, so sort out a price & I'll send you a cheque. You're a real star mate. Thank you.
Another component slots into place. It's slowly coming together.  ;D


Title: Re: Manky's Pop.
Post by: lunatic on June 05, 2009, 06:02:31 PM
Ooh, thats a lovely knob!  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 10, 2009, 02:40:52 PM
Looking for someone to make me a set of stainless V8 Rover exhaust headers to my pattern. Anyone know of a fast & reliable builder? Anywhere in the South of England would be O.K


Title: Re: Manky's Pop.
Post by: spanners on June 10, 2009, 08:12:38 PM
Looking for someone to make me a set of stainless V8 Rover exhaust headers to my pattern. Anyone know of a fast & reliable builder? Anywhere in the South of England would be O.K

 this might be a shot in the dark but have you tried rimmer bro,s   rover v8 peeps    may be a bit expensive  could be worth a look


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 10, 2009, 08:56:12 PM
Didn't know Rimmers did Rover stuff -I've used them for Triumph parts before. Will give them a try. I can buy standard Range Rover headers from several places but I need a custom set made. Got to be wider than normal to clear my chassis. Standard ones aren't a matched pair either.


Title: Re: Manky's Pop.
Post by: BikerGran on June 10, 2009, 09:09:38 PM
Bit expensive but know their stuff - http://xgenuk.com/exhaustpipe.asp (http://xgenuk.com/exhaustpipe.asp)

Hm, they were called X-Generation last itme I was there, now they appear to be Blue Sky Concepts.  I think I know why but it has nothing to do with the quality of their stuff!  They're in Poole.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 10, 2009, 09:16:49 PM
Hmm, they look very professional -which usually means very expensive, but certainly worth a phone call. Thanks Bobbi.


Title: Re: Manky's Pop.
Post by: goforest on June 11, 2009, 12:55:55 PM
Theres a bloke round the corner from me don't no him but could be a friend of a friend type thing I'll check it out


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 11, 2009, 07:32:29 PM
Thanks Paul.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 12, 2009, 05:33:54 PM
To comply with SVA regulations the Pop will need side repeaters for the indicators. I've been playing with various motorcycle ones for a while but eventually plumped for these from Europa Spares, who specialise in kit car parts.
www.europaspares.com
Loony thinks they're actually VW Golf units, possibly mark 3. The Pop was originally fitted with small hinged air vents on either side of the body, opened with a lever from inside the car. Mine was missing the actual flaps when I bought it, so Madron molded some new ones in fibreglass for me. Seemed the obvious place to mount the repeaters as anywhere else would spoil the lines of the bodywork. I'll remove the hinges & bond the 'glass panels permanently in place. It seemes a shame to lose an original feature of the car, but then we've already chopped it in half so what am I worrying about?!


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 12, 2009, 05:38:00 PM
Only had a couple of hours at the workshop ths afternoon, so finished off by cutting the first chassis cross member -completely the wrong length. Bugger. Measure twice, then measure again. Never mind, I can use the off-cut elsewhere so it won't be wasted. I'll try & get it right tomorrow.


Title: Re: Manky's Pop.
Post by: panthershaun on June 12, 2009, 05:55:42 PM
keep the nice opening airvents Andy and just mount the lights on them ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 12, 2009, 06:09:52 PM
That was the original plan, but as you can see from the side-on view, they're too deep. The panel hinges go right across the opening so even LEDs would foul. I've tried lights everywhere else I can think of & they just look wrong. A necessary addition to get through the test, so I'm happy to put them here -at least they look like they're supposed to be there, rather than just plonked on anywhere as an afterthought.
Think I've also got to fit a reversing light & fog light. Loony would like them on hinged mounts under the rear tailgate so they can be hidden away after the test, but I figure if I've got to have them, they might as well be fitted properly, in the panel under the tailgate, probably just using a red & white version of the tail lights I've already got.
For anyone following this, there's a comprehensive run-down on what's needed for the commercial SVA test in the new issue of Custom Car magazine, (available in the shops from today). No new BritChopper mags at Loony headquarters yet Shaun.


Title: Re: Manky's Pop.
Post by: panthershaun on June 13, 2009, 04:52:21 PM
should be today mate, unless the postie's slow  ::) ::) ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 13, 2009, 08:27:36 PM
The Postie was too quick -got to Loony's workshop before he did & left a card to say he'd called. Different sorting office to the one I work in, so Loony will have to go & collect them on Monday.
Got to bed at 1.0.clock this morning, then up again at 3.30am to go to work, then an afternoon spent hacksawing metal in the workshop in the sweltering heat, so I'm knackered now. I'm getting too old to burn the candle at one end, let alone both.
Anyway, today I cut 4 angled cross members for the Pop & Loony tacked them in place. These will brace the gearbox cross member & should stop any torsional twisting of the chassis when we drag race it, carefully road test it.
I've been peering under the bodies of various hotrods this Summer & have to say, even some of the prettiest examples have suprisingly flimsy looking chassis. Ours is built like a Sherman tank compared to many, but I'd rather over-engineer than have it hop, skip & jump it's way down the road. The main chassis legs are 40mm x 80mm, 4mm wall thickness. The new cross members are 40 x 80, 3mm. 
Next job is a protective loop around the propshaft, (a very sensible precaution -if the prop breaks loose it won't be much fun flailing around inside the car at several thousand rpm). Still waiting for the new prop to be finished at Reco-Prop in Luton at the moment though. Also need to make up some outriggers to attach the outer bodywork to, but need to know where the exhaust system's going to run before we can do that so I need to find someone to make up the headers.    


Title: Re: Manky's Pop.
Post by: panthershaun on June 14, 2009, 09:14:46 AM
looking good mate, once my bodies done that's my next job  :-\ :-\ :-\ :-\
I'll pm you about those pop pedals and where I will hide them if you need to collect before I'm back ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 14, 2009, 07:19:24 PM
Right-o.
Picked up a couple of bits & pieces from the autojumble at the Wiltshire Steam Rally today.
A pair of new reproduction tractor number plate lights for a fiver each.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 14, 2009, 07:21:07 PM
And an MG handbrake lever for 5 quid.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 14, 2009, 07:21:41 PM
.


Title: Re: Manky's Pop.
Post by: tbone on June 14, 2009, 08:39:29 PM
i really like the look of the mg lever, would have used one on my trike except for the fact they have that open back.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 14, 2009, 09:01:02 PM
My first thought was whether I could weld a plate or section of tube along the back face, but then if the mechanism failed you wouldn't be able to repair it. It's designed to sit along the side of the transmission tunnel so the back face is hidden from view. The chrome's a bit pickled so I'll probably blast it & powder-coat it black.


Title: Re: Manky's Pop.
Post by: panthershaun on June 14, 2009, 09:09:21 PM
The chrome's a bit pickled so I'll probably blast it & powder-coat it black.

that's patina  ::) ::) ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 14, 2009, 10:12:54 PM
Patina -posh word for rust.  :P A certain amount's cool. Beyond that it's just knackered.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 18, 2009, 10:20:10 PM
God I'm utterly pooped.
Just picked up the new prop-shaft from Reco-Prop in Luton. Unfortunately that involved travelling -well, parking, on the infamous M25. Got up for work at 4.30 this morning. Left home at 5, finished work in Basingstoke at 2.30. Hit the M3 towards London at 3. Reached Luton at 4.40, 20 minutes before they closed for the day. Cool. Picked up the prop -very nice, thank you. 5 minutes later I'm back in the car & heading home. Four hours later I finally get back. I've been sat in my car for the best part of 6 hours. The bloody M25 was shut, with a 20 mile, completely stationary traffic queue. I was in the middle of it.
Prop-shaft safely collected. Time for bed.


Title: Re: Manky's Pop.
Post by: XJ750(UK) on June 18, 2009, 10:27:51 PM
Right-o.
Picked up a couple of bits & pieces from the autojumble at the Wiltshire Steam Rally today.
A pair of new reproduction tractor number plate lights for a fiver each.
They're dash lights off a Massey Ferguson 165 unless I'm very much mistaken  ;) sorry, just slipped my anorak on again ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 18, 2009, 10:28:46 PM
Really? Cool!


Title: Re: Manky's Pop.
Post by: BikerGran on June 19, 2009, 12:37:39 AM
Could hardly be a worse time of day to travel, or a worse route to do that time of day!   :-\


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 20, 2009, 01:18:48 PM
Now you tell me! Going North to Luton was fine. It was the return journey that was such a bugger. Roadworks plus an accident just where the M1 meets the M25. They shut the motorway slip roads in front & behind me. Sat in the car, listening to radio traffic reports saying whatever you do, don't go near the M25. Poo. Spent about an hour completely stationary & another hour slipping the clutch, creeping forward a few inches at a time. At least I got what I went up there for.
Prop-shaft now fitted with a couple of temporary bolts to check the length. Reco-Prop used the rear flange from the original Sherpa prop, but the rest is all new. 3 inch diameter with a sliding joint at the front -it's too short. Now it's too long. Perfect.  :)
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 20, 2009, 01:19:22 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 20, 2009, 01:26:38 PM
Also received a parcel from "Pop Browns" -suppliers of custom & restoration parts for Pops & Prefects. I bought an alternator bracket & new fan belt, to relocate the alternator from high up on the off-side of the engine, to low down on the near-side. A nicely shaped, half inch thick, plasma cut bracket, slotted adjuster arm & new mounting bolts. Fitted perfectly. Thanks Chris. The alternator's now tucked inside the line of the chassis rail & fills an otherwise empty space, matching the steering box location on the other side of the chassis. Result. The coil's just hung from it's wires at the moment, but we'll probably bolt it to the bulkhead, in the recess behind the cylinder heads. Lots of bits are just temporarily propped in place for the time being, so all need mounting tabs & brackets made.
Next job is to find someone to re-make our bodged up exhaust header samples in stainless & then sort out the pedals. We've got a selection of pedals to experiment with now, but Spanners, if you read this, can you look out those 100E ones for me please mate.  ;)


Title: Re: Manky's Pop.
Post by: voodoo on June 20, 2009, 08:30:48 PM
Sweet looking motor,I just love classic trucks......would love to do another Rod but now dont have the joys of a garage and dont fancy the idea of building one on my drive,its bad enough doing bikes under my little Parambulator shelter.....Voodoo.....


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 20, 2009, 09:24:34 PM
Not sure mine could be called a "classic"!
I bought the engine as a runner from a friend of a friend. Didn't come with a log book & there was some talk of it being raced at some point. 1970s Rover SD1 bottom end, (think the old fashioned "Jam Sandwich" Police cars), with Range Rover heads & a Rover P6 auto box. We'll repaint the cases in black & polish the ally bits. Just hope the engine numbers check out O.K when it comes to registering the truck. Wouldn't be difficult to find another engine if necessary but hopefully it's all legit. PantherShaun posted a short vid of it running on YouTube

http://www.youtube.com/watch?v=z0RTqZDSuDU

There are guys here building all sorts of projects in very limited circumstances. Inspires me just as much as everyone else.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 23, 2009, 10:17:01 PM
A change of plan on the propshaft loop. This goes around the propshaft to contain it should it break loose -stops it either dropping & digging into the road or flailing around inside the car. A must for racing & a sensible precaution for road cars.
I made a loop from 1" bore ERW tube a while ago. Now we're going for a box section chassis cross member with short box section uprights either side of the prop connecting to the cross member at the base of the cab, forming a square box around the shaft.
This afternoon, after work, I cut the cross member & scalloped out some extra clearance to allow for suspension travel. The open top face was filled with 4mm flat strap bent to suit & the whole caboodle tack-welded in place by young Lunatic.
Got home from work to find a large parcel from Doc, (Twisted Patience), containing the reworked gearstick. Lovely workmanship as always Doc. Huge thanks. I'll take a photo of it in the daylight tomorrow.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 24, 2009, 07:40:00 AM
Gearstick, courtesy of Doc.
This is the standard Rover P6 gearchange, but I fancied something a little different. We use snooker balls for gear knobs on our trikes & I had a couple of red ones left over. I sent it down to Doc in Somerset with the technical instructions -Make this fit this & work please. Amazingly, he did. I now have a red snooker ball gear knob with a nice polished stainless steel lock-out button set into the top of it.
I'm planning on doing the chassis & all the running gear in gloss black powder-coat, with a satin black body & black interior, but as the red logos will be on the doors, (hopefully an airbrushed version of the current vinyl stickers), there'll be red detailing here & there. Next job will be to make a bracket to mount the stick to the top of the gearbox itself.


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 24, 2009, 08:13:08 PM
Called in at Loonyville on our way back from Oxford today -Taz & I drove for 2 hours to see the guy who's making the aluminium mudguards. We took a front & back wheel for him to try them on. Took him just a matter of minutes to sit them on the tyres & say ahh, thought so, then we were back in the car & heading off to find a nice pub for lunch. Guards should be finished by next week.
After bolting the wheels back on the Pop, I cut the uprights to go either side of the prop-shaft & Loony tacked them in place. Gonna be the strongest chassis in the World by the time we've finished.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 24, 2009, 08:14:01 PM
.


Title: Re: Manky's Pop.
Post by: TwistedPatience on June 24, 2009, 08:37:55 PM
Did you find the brass button in the bag Andy. Just in case you change your mind ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 24, 2009, 08:49:31 PM
Ney, ney & thrice ney!!
-but thanks anyway Doc.  ;)
Gonna bring the truck down your way for a bit o' cruisin when we're done. ;)


Title: Re: Manky's Pop.
Post by: TwistedPatience on June 24, 2009, 09:00:48 PM
I'll take that as a NO then :P


Title: Re: Manky's Pop.
Post by: tazet on June 24, 2009, 09:05:07 PM
What ever made you think that  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 25, 2009, 10:05:17 PM
Doc's rather spiffing gear change hooked up to the linkage & propped in place on top of the auto box.
The position is good in relation to the steering wheel but I might have to move the seat a little further forward than originally planned -at least I'll have room behind it to stow a jacket & a packet of sarnies. A long, hot, sweaty day at work today, trudging the streets delivering the mail, so didn't spend too long at the workshop. Long enough to start marking out & cutting a mounting plate for the shift mechanism.


Title: Re: Manky's Pop.
Post by: Mr_G on June 25, 2009, 10:43:00 PM
Doc's rather spiffing gear change hooked up to the linkage & propped in place on top of the auto box.
The position is good in relation to the steering wheel but I might have to move the seat a little further forward than originally planned -at least I'll have room behind it to stow a jacket & a packet of sarnies. A long, hot, sweaty day at work today, trudging the streets delivering the mail, so didn't spend too long at the workshop. Long enough to start marking out & cutting a mounting plate for the shift mechanism.

And some Jaffacakes no doubt.  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 25, 2009, 10:59:17 PM
Maybe we should build a special Jaffa rack.


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on June 26, 2009, 09:28:11 AM
Maybe you should enquire about sponsorship,i bet those two words do'nt get mentioned as much in the Jaffa factory,as they do on here. ;D


Title: Re: Manky's Pop.
Post by: poprodder on June 26, 2009, 04:38:01 PM
some excellent progress there,

is this a jaffa rack!!! :P ;D

(http://media.funlol.com/content/img/orange-boobs.jpg)


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 26, 2009, 08:48:01 PM
Tasteful!


Title: Re: Manky's Pop.
Post by: poprodder on June 26, 2009, 09:41:42 PM
mouthfull!!!  :D


Title: Re: Manky's Pop.
Post by: Mr_G on June 26, 2009, 10:14:17 PM
 :P


Title: Re: Manky's Pop.
Post by: Hagar on June 27, 2009, 01:34:31 AM
MMMmm  there's nothing like  freshly squeezed orange juice  .....   ;D


  ..  Hagar  ..   ;D


Title: Re: Manky's Pop.
Post by: panthershaun on June 27, 2009, 07:26:51 AM
looking good Andy,


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on June 29, 2009, 05:41:23 PM
Thats really taking shape Andy boy ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on June 29, 2009, 09:45:20 PM
'Ello mate. Welcome back.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 01, 2009, 06:39:56 PM
Another seriously hot day delivering the mail today. After 4 hours sorting the mail at the depot & another 4 traipsing round the streets with it, I really didn't have the energy to do much today.
Started making a mounting plate for the gearchange from offcuts of 3mm steel. I was a bit concerned that if we positioned it where the rod that connects it to the gearbox dictates, it would be a bit of a stretch to use. So I've brought it back a few inches & will use 4 conveniently placed bolts on the back of the box to mount it from. I'll have a new, slightly longer connecting rod made up. All this is, is a platform to mount the selector to. It'll be covered by the gearbox tunnel when we get as far as adding the floors. We wrapped the shiny red gear knob in masking tape to avoid scratching it as much as poss.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 08, 2009, 10:14:46 PM
Thanks to Mr PantherShaun, I now have an under dashboard mounting handbrake lever. I've got a selection of levers but not enough room on the floor for any of them, so Shaun sent me an original Pop one, which pulls out from under the dash. It's basically a tube with a series of notches down it's length & a rod that pulls against a spring. The cable hooks into the bottom of the rod so is pulled as the rod moves up the tube.
Many thanks for that Shaun. I owe you one.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 08, 2009, 10:28:35 PM
After much discussion yesterday, we've decided on a design for the brake pedal, using a cut down original Pop one courtesy of Shaun. Having decided on it's length, (5 inches), I welded in a pivot cunningly recycled from a motorcycle front wheel spindle spacer.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 08, 2009, 10:36:03 PM
On advice from Loony's Dad, (a qualified engineering type), I then plated either side with some offcuts of 4mm box. Next job is to PM Doc to machine up some bronze bushes for the pivot. The lever will pivot inside a length of box section welded to the chassis.


Title: Re: Manky's Pop.
Post by: TwistedPatience on July 09, 2009, 05:46:40 AM
Lucky I've got some bronze left then init. ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 09, 2009, 05:40:10 PM
Hiya Doc  ;D
I'll email you the dimensions then. Thanks mate.


Title: Re: Manky's Pop.
Post by: panthershaun on July 09, 2009, 08:24:36 PM
Thanks to Mr PantherShaun,

No problem mate  8) more high quality items supplied by In-the-shed Speed Shop  ;D ;D ;D


Title: Re: Manky's Pop.
Post by: poprodder on July 11, 2009, 06:09:44 PM
recycling at its best, who needs the scrappage scheme.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 14, 2009, 10:12:52 PM
Took the gearchange mount back out again today, sliced the corner off it & welded a fill-in piece back in. Just gives us a bit more leg room that's all. Squirted a little grey paint on it to keep the surface rust at bay & bolted it back in. Then took the extended selector rod to my mate Reg to have a new one machined up in stainless.
I also made a start on a pedal box to hold the brake pedal, fashioned from an off-cut of chassis box section.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 15, 2009, 06:06:44 PM
Chopped up part of the linkage from the original Pop pedals today & re-worked it into a drop arm & clevis for the brake pedal. Ideally the pedal should be 5 inches long & the drop arm 1 inch to give a 5 to 1 ratio. Ours is 5 inches & 2 inches, so 2 1/2 to 1. Haven't got the room to make things any longer. We're planning on fitting a remote servo under the pick-up bed though so hopefully shouldn't be a major problem. Next job is to remove a dual circuit master cylinder from one of Loony's old scrap VWs, mount it on the chassis & hook it up to the pedal.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 15, 2009, 06:20:29 PM
Just checked our postbox outside the cottage & there was a package from Pop Browns in Essex. A pair of "Bullseye" pedal rubbers & mounting pads. At 3 inch diameter. they look huge, but as Taz says, they're smaller than the width of my shoe, so if they won't fit in the footwell of the truck, neither will my feet.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 18, 2009, 10:23:44 PM
Taz & my day off today. Had a call from Darren the mudguard guy to say my Pop guards were ready. So it was off to Oxford for the afternoon.
Very pleased with them. Hand made in aluminium to fit my tall skinny cross-plies. Radiused ends, wired edges, curved profile, & a raised bead down the centre. Nice.


Title: Re: Manky's Pop.
Post by: poprodder on July 18, 2009, 10:51:27 PM
i like them a lot. 8)


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 18, 2009, 11:16:47 PM
Thanks.  :)
I wanted something with a bit more shape to it than just a flat trailer guard. Could've had Madron create me some in fibreglass but I want to keep the Pop all steel if I can. I looked at reproduction steel bike guards with a similar raised bead, but apart from them being the wrong diameter, they were around 90 quid each. These cost me 45 quid a piece. 50 if I wanted them polished.
I plan to fit the front indicators to the leading edge of the front guards, so Darren left a break in the beads for them to sit in. The bulb holders & lenses are from Stafford Vehicle Components. White frosted glass lenses with orange bulbs. They're designed to fit repro sidelights as used on early Jags, Rileys, MGs etc. I'm hoping to make my own ali bodies though & blend them into the guards. Eventually the guards will be mounted on tubular struts & powder-coated satin black.    

Brooklands Bodycraft.
Darren Goodgame.
01865 451914
07790 286229


Title: Re: Manky's Pop.
Post by: texon on July 19, 2009, 06:32:16 PM
they look sweeeeeeeeet  ;) and yes I am still hear :D and look in all the time to keep my eyes ::) on the builds


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 19, 2009, 07:17:15 PM
Hello mate.  ;) We get a lot of visitors who prefer to read rather than write. Fine by us, but if we ain't covering the stuff you want us to, you have to get involved & speak up.  :)
Mr Goodgame the mudguard guy had a stand at the last Beaulieu autojumble I went to. He was displaying an aluminium body he'd built for a Riley tourer. Lovely workmanship. As well as mudguards & the like he can also punch louvres, add swages, all sorts of clever stuff.   


Title: Re: Manky's Pop.
Post by: poprodder on July 19, 2009, 10:04:20 PM
i wondered what the gap was on the beading.
plain metal trailer arches for mine(in the boot of course!!!)


Title: Re: Manky's Pop.
Post by: panthershaun on July 20, 2009, 02:36:58 PM
and mine  ;D that Manky can be a posh git  ::) ::) ::) :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 20, 2009, 09:31:35 PM
He'll be wanting a roof & windows next.  :P
Tried the guards on the tyres this afternoon. They look rather good, in my slightly biased opinion. They'll sit an inch or so off the rubber when they're fitted.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 20, 2009, 09:32:55 PM
Rear guards-
towards the front?


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 20, 2009, 09:33:25 PM
Or central?


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 20, 2009, 09:33:56 PM
Or to the back?


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 20, 2009, 09:35:12 PM
The front indicators will sit about here on the front guards.


Title: Re: Manky's Pop.
Post by: poprodder on July 20, 2009, 10:11:32 PM
rears to the rear, unless you want rooster tails!!!
they look extremely sexy in a strange way :o


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 20, 2009, 10:41:50 PM
So do I, I'm told.  :P


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on July 21, 2009, 03:35:59 PM
I wish i'd never seen those guards,i can feel a bit of angle grinder frenzy coming on.

IMO the guards need to be low edge towards the center of the car,as in the first pic. 8)


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 21, 2009, 05:24:47 PM
Yeah, I was thinking the same. Could still be persuaded otherwise, but I reckon they're going to throw up plumes of water in heavy rain where ever I put them.
Took the front guards & the light units over to my mate Berni Andrews of Project Fabrications in Newbury, Berks after work today. Hopefully he'll make me a pair of "pods" to house the bulb holders & lenses that will blend into the top of the guards fairly unobtrusively.
I also picked up a stainless linking rod for the gear change from my mate Reg in Basingstoke, Hants. Machined from 10mm rod for a fiver. Now fitted & working. 
No, I haven't got a toffee apple for a gear change :)


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on July 22, 2009, 09:30:20 AM
We know,it's a poppy,is'nt it ? ;D


Title: Re: Manky's Pop.
Post by: Hillbilly Deluxe on July 22, 2009, 09:45:36 AM
We know,it's a poppy,is'nt it ? ;D

Btw,im not really interested in cars,as such,but im following this thread,and a couple of others with real interest.

Can i ask what may be to you car guys seem like a stupid question ?

There are lots of powerfull modern rear wheel drive engines,so why are Rover motors still the motor of choice ? Why not use something like a carburetted BMW straight 6 for example ? Something like the motor out of my Landcruiser V6-3.4L ? apart from it being 4WD,tons of torque,Quick,reliable,V sound.Surely it can't be because of all the electric gubbins that go with the motor ?I would think that if a car is built basically from scratch,like you are doing,then electrics would'nt be a real problem.

It's just a thought.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on July 22, 2009, 05:15:29 PM
muddies and lights look bloody great m8


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 22, 2009, 07:21:24 PM
Thanks Gareth  ;)
No real reason H/Billy. Just can't beat the unmistakeable rumble of a V8. The Rover motor is an old Buick design, (I've got the carb manifold from a Buick on mine), & is the closest we Brits can get to the traditional Yank V8s. Much as we like to think the British custom scene is completely our own, we still tend to follow the fads & trends of our cousins across the pond, same as we do with custom bikes.
Rovers are all aluminium so pretty light compared to other similar sized engines, which makes them perfect for smaller British cars.
Hotrods are supposed to be basic, stripped down & built to go, so the simpler the design the better.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 23, 2009, 10:10:02 PM
Having established where the brake pedal's going to mount on the chassis, it's time to move on to the master cylinder. Loony donated a dual circuit cylinder from one of his collection of scrap VW Beetles, (the SVA test insists on dual circuit brakes, front & back). As the piston is pushed into the bore, the rear brakes are fed first, followed by the fronts. It also includes a hydraulic brakelight switch.
It needs to sit under the floor between the seat & pedal. So I cut a short length of box section & bored & filed a mounting hole in it for the nose of the cylinder. Drilled 2 bolt holes, welded a pair of captive nuts to the back of the box, then a couple of tubes inside to prevent it being crushed by over enthusiastic spannering. Now it just needs cutting to length & welding into the chassis.


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 23, 2009, 10:24:58 PM
I planned to buy a rebuild kit for the cylinder, but a visit to Beetlelink in Farnham, followed by the local branch of German, Swedish & French, showed that they don't stock them any more. So I ended up ordering a new one. 75 quid. Maybe sounds a lot, but I'd kinda like to be able to stop, so worth it as far as I'm concerned. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 23, 2009, 10:43:36 PM
Bugger! Brock's just emailed me a link to a firm in Brighton who sell the same cylinders for half the price!
I'll phone & cancel the order tomorrow then buy from them. Can use the old cylinder as a pattern to build from until the new one arrives.


Title: Re: Manky's Pop.
Post by: brock on July 23, 2009, 10:50:03 PM
 ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 25, 2009, 03:02:19 PM
Well, I cancelled my original order, then rang Brock's suggestion & ordered a cylinder from them. With the brake light switch & it's protective rubber boot, plus VAT on all 3 bits, plus postage, it worked out to exactly the same price, to the penny, as my original order!


Title: Re: Manky's Pop.
Post by: Manky Monkey on July 27, 2009, 07:52:24 PM
Dual circuit brake master cylinder arrived from VW Heritage Parts Centre today.
The photo online shows it with the brake light fitted. Does it come with one or do I have to order it seperately?
Order it seperately Sir.
Of course, it came with one, so now I have a spare.
Also received a brand new dual reservoir with built-in test button in the cap from Merlin Motorsport. The SVA registration test requires a warning light on the dashboard for low brake fluid level & a means of testing that the bulb in the warning light hasn't blown, plus a visible fluid level reading. Doesn't say whether the test button has to be on the dash, so I'm hoping we can mount the reservoir under the driver's seat, with a removable seat base to give access to the test button.
No obvious way of mounting this reservoir. Looks like I'll have to cut a hole in a wide 3mm plate bracket for it to drop into.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 01, 2009, 02:22:47 PM
Cut the chassis cross-member back out, chopped it about a bit & added the m/cyclinder & pedal mounts.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 01, 2009, 02:24:29 PM
Tack welded back in the car. Now I need to get a new connecting rod made up to hook the pedal to the cylinder.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 02, 2009, 10:06:13 AM
Had a parcel yesterday from Trev Dorrington of Race Ready Engineering
raceready@tesco.net
He had a stall at the NSRA swapmeet back in March & also happens to belong to the same muscle car forum Taz does. He's machined me a jolly nice adaptor plate to fit my Holley carb to the Buick manifold on my Rover motor. The manifold is angled down towards the front by about an inch but the carb needs to sit level. A lot of Rover engined rods get round this by fitting the engine nose up. I think that looks a little odd though so would rather angle the carb. Trev had some problems with his CNC machine, which caused a backlog in his work schedule, but has produced this angled adaptor at a very reasonable price & even threw in a bag of mounting bolts. Give him a shout if you need anything similar.  


Title: Re: Manky's Pop.
Post by: poprodder on August 02, 2009, 10:11:43 AM
nice work there.
 :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 03, 2009, 09:18:32 PM
My rebuilt Holley carb, finally bolted to the Buick manifold that's bolted to the Rover engine.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 03, 2009, 09:19:36 PM
Never leave your camera unattended in Loony's workshop.  :o


Title: Re: Manky's Pop.
Post by: TwistedPatience on August 04, 2009, 05:56:13 AM
Ha Ha!


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 11, 2009, 11:13:38 PM
Threw together a mounting bracket this evening for the dual brake fluid reservoir.
It's very rough but will do the job with a bit of tidying up. Cut from 3mm plate, the reservoir sits in a cut-out in the top so that the Hi/Lo fluid levels are visible. It'll be retained with a rubber strap -I've just ordered a short motorcycle battery strap from Ebay so will add securing hooks or tabs as appropriate when it turns up. The bracket will be welded to the chassis & will sit below the driver's seat, accessed by removing the seat cushion. It'll be slightly higher than the master cylinder. The SVA building regs say the car must be fitted with dual circuit brakes, either split front & back or diagonally. There must be a low fluid warning light in sight of the driver & a means of testing it -this reservoir has a test button built into the filler cap.
I've been looking for a dual circuit remote servo. Don't want a big modern servo unit in the engine bay, spoiling the pseudo 50s hotrod look, so a remote one could be mounted under the pick up bed, but it seems they only come in single circuit variety. At about 140 quid each I'm not fitting 2 of them, so we'll probably go without & just have to stomp on the brake pedal a bit harder.


Title: Re: Manky's Pop.
Post by: TwistedPatience on August 16, 2009, 01:42:18 PM
Pop pedal bearings are done, headstock collars next.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 16, 2009, 06:03:48 PM
Woo hoo! Thanks Doc.
Haven't got a photo of it, but got the brake pedal pushrod sorted now too, so we can hook the pedal up to the master cylinder & see how it feels. Next job will be to rebuild the front calipers & rear drums & see if we can get some brakes working on this thing. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 17, 2009, 10:22:42 PM
Struggling as ever to find spare time to work on any of our projects, I started on a tie-down strap for the brake reservoir this evening. I'd bought a rubber scooter battery strap from Ebay for a couple of quid, but it turned out to be too long. Revised plan saw me bending a bit of polished stainless strap up instead. This will hook onto a tab at the back of the reservoir & be held with a nut & bolt at the front. Probably with a thin rubber cushion between strap & cap.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 18, 2009, 10:45:30 PM
Strap finished at Loony's workshop today.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 18, 2009, 10:48:13 PM
And completed unit tack-welded in place on the chassis. The reservoir will sit below the driver's seat, accessed by lifting out the seat base. Ahead of the reservoir is the dual circuit VW Beetle master cylinder & in front of that, the brake pedal.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 18, 2009, 10:49:10 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 21, 2009, 10:53:08 PM
Had a delivery from Rimmer Brothers, the Triumph spares guys today.
A brand new pair of Triumph Vitesse front brake calipers. The ones I had were sold to me as Vitesse but are actually Triumph Herald units -smaller calipers, which mean they don't fit the new Vitesse discs I bought. Also explains why I had to bugger about with the hubs to get them to fit my Pop axle, when everyone told me they should fit straight on. In addition, the new pads I bought wouldn't fit the Herald calipers. Just in case you need to know, Herald calipers are stamped as Type 12 or 14. Vitesse are Type 16A or 16B.
Unfortunately the bigger calipers mean I'll have to make new, bigger mounting plates. Ah well.
These babies should stop the Pop.  :)


Title: Re: Manky's Pop.
Post by: panthershaun on August 22, 2009, 10:34:26 AM
I'll have to make new, bigger mounting plates. Ah well.
can I have the old ones please  :-* :-* :-* save me some time on the ones you sent me plus I have another Pop axle sitting in the wings waiting for another day  ;) ;) ;)

I didn't realise that Vitesse were so different from Herald/Spitfire  ??? ??? ???


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 22, 2009, 02:09:10 PM
Neither did I. Lunatic wasn't at his workshop today, so I haven't been able to compare the 2 sets of calipers yet. Biggest concern is whether the new, bigger calipers will fit inside the wheel rims. Yup, I'll post you the old mounting plates when I take them off Shaun.


Title: Re: Manky's Pop.
Post by: poprodder on August 22, 2009, 05:28:17 PM
herald/spitfire hub 41mm, vitesse are 45mm.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 22, 2009, 11:22:55 PM
Now he tells me!  :P


Title: Re: Manky's Pop.
Post by: poprodder on August 23, 2009, 10:47:30 AM
 ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 24, 2009, 07:29:13 PM
Shiny new Triumph Vitesse caliper. Cruddy old Triumph Herald one. The Vitesse units have much bigger pistons & work with bigger diameter, thicker discs.
Took the new calipers to Loony's workshop after work today, along with some offcuts of steel plate to make the carrier brackets. Unfortunately I need to fit the pads so that I can see how far the calipers sit over the discs, but the new pads, pistons & pins I bought a while ago turned out to be for the Herald brakes. Bugger. So got to order new pads tomorrow.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 24, 2009, 07:33:31 PM
Loony's Dad pointed out today that the lowest part of the brake master cylinder -& possibly the lowest part of the finished car, would be the hydraulic brake light switch. It hangs about an inch & a half below the chassis rails. One whack on a speed bump or pothole would rip it straight off, dumping all the brake fluid on the road in about 2 seconds flat. So I'll fit a blanking bolt & an inline switch somewhere on the front end.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 25, 2009, 11:01:30 PM
PD came up with a set of Vitesse pads today, (he's a professional mechanic & rang around the local auto factors for me, then delivered them to Loony's workshop. Thanks dude). So I was able to sit the calipers over the discs in the correct position & measure up for new, thicker mounting plates.
Marked them out on some 5/16" plate, (about 8mm), & began chain drilling them out.


Title: Re: Manky's Pop.
Post by: poprodder on August 26, 2009, 11:50:12 AM
what you doing with old ones? ;) ;D
cheers chris.


Title: Re: Manky's Pop.
Post by: panthershaun on August 26, 2009, 03:19:04 PM
sorry dude, already bagged  ;) ;) ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 26, 2009, 04:14:27 PM
Yeah, sorry Chris, Magpie Shaun got there before you. The old plates were 1/4", (6mm), which I reckon would be strong enough as the majority of the stresses should be rotational, rather than across the plate when you brake. The new mounting plates are virtually identical in shape but the calipers are bigger & heavier so it seemed sensible to go for thicker plates.
So I've now got what I think are Triumph Herald hubs, re-studded to take the Hillman Minx front wheels, with a mix n match set of bearings to fit the Ford Pop axle, with Triumph Vitesse discs & calipers.
If anyone's running type 12 or 14 Herald front calipers I have brand new pistons, seals, pads & pad mounting pins for sale, plus old calipers & discs. Make me an offer.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 26, 2009, 08:04:36 PM
.


Title: Re: Manky's Pop.
Post by: poprodder on August 26, 2009, 09:47:02 PM
that looks hard work!!! :o


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 26, 2009, 10:43:12 PM
I am nothing if not stupid.
-yes, it is.


Title: Re: Manky's Pop.
Post by: poprodder on August 29, 2009, 03:35:51 PM
i could be doing that for next project :o :o ..........better finish this one first!!! ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 29, 2009, 04:02:54 PM
You mean using Triumph Herald brakes Chris? These are surplus to requirements now as the parts don't fit my new Vitesse brakes. Also got the Herald spindles they came off. Complete front brake kit. I'm sure we could agree a sensible price if you want them.  ;)


Title: Re: Manky's Pop.
Post by: poprodder on August 29, 2009, 04:24:37 PM
i've a yard full of triumph bits!!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 29, 2009, 07:19:04 PM
Bugger.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 30, 2009, 10:00:03 PM
8 mill thick steel plate. Sheesh. A whole afternoon's work just to open out the central spindle hole & drill the mounting holes. I've also scalloped the back edge of the plates to clear the caliper pistons. I need to add a pair of spacers to sit the caliper over the centre of the disc. My mate Reg with the lathe in his shed is going to machine up a couple of 6mm washers which I'll weld to the plates, then tap 1/2" threads into the resulting 14mm thickness.


Title: Re: Manky's Pop.
Post by: Manky Monkey on August 31, 2009, 10:44:41 PM
I've been at a local steam fair today. Picked up a pair of replica "International" tractor silencers for 20 quid each. Looking down them, they've got a plate across the bore, forcing the gases through the perforated tube around the edge. I'm hoping that'll make them quieter than the Cherry Bombs I've tried before. Not sure what it'll do for back pressure, or whether these are too small a bore for the down pipes, but for the price, worth a try.


Title: Re: Manky's Pop.
Post by: poprodder on September 01, 2009, 06:12:48 PM
stack exhausts!!! :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 01, 2009, 11:11:15 PM
Ha, ha, ha ...no.


Title: Re: Manky's Pop.
Post by: poprodder on September 02, 2009, 06:45:44 PM
(http://www.bikernet.com/news/images/PhotoID25340.jpg)

 ;D lol


Title: Re: Manky's Pop.
Post by: TwistedPatience on September 02, 2009, 07:03:07 PM
Now that I do like! that's so KOOL!!! ;D


Title: Re: Manky's Pop.
Post by: panthershaun on September 02, 2009, 09:11:33 PM
(http://www.bikernet.com/news/images/PhotoID25340.jpg)

 ;D lol

 :-X :-X :-X :-X :-X nuff said  :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 02, 2009, 11:01:53 PM
No, no, no, no, no!!!   :o


Title: Re: Manky's Pop.
Post by: poprodder on September 03, 2009, 04:38:21 PM
he he!!! ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 07, 2009, 06:18:29 PM
First afternoon at Loony's workshop for a week or so. I've welded the spacers to the brake caliper plates & spent an hour or so hacksawing them roughly to shape. Fortunately they fit.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 07, 2009, 06:32:25 PM
With the disc sat on the hub I found the back of the wheel studs needed a quick fettle with the grinder to clear the caliper. The spacers I added to the back of the plates also need shaving by about a millimetre to sit the caliper centrally over the discs. Other than that though, everything seems hunky dory -whatever that is. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 07, 2009, 06:40:43 PM
Much bigger & betterer brakes. And the wheels still fit over them, which is nice.
A bit of tidying up with the grinder & file & they'll do the job.


Title: Re: Manky's Pop.
Post by: poprodder on September 07, 2009, 06:55:17 PM
nice work, i've got no such problems, i just bolt everything on! :P ;D


Title: Re: Manky's Pop.
Post by: Mr_G on September 07, 2009, 10:07:53 PM
Nice work, looking good Andy!


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 17, 2009, 11:19:09 PM
Things don't look much different, but the extra millimetre has been shaved off to sit the calipers centrally over the discs & the plates have been tidied up with a hand file. I've been carting these damn calipers & plates back & forth  between Loony's workshop & my shed for weeks now, trying to find a spare hour or two to finish them. Hopefully they're done now.
I've also had cone shaped spacers made up to fit the bottom of the radius arms where they pass through the axle. You can't see them, but they're there.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 17, 2009, 11:21:31 PM
8.30 in the evening & it's already pitch black at Loony's lair. Winter's on it's way.


Title: Re: Manky's Pop.
Post by: panthershaun on September 18, 2009, 03:21:22 PM
cool photo mate  8) 8) 8) 8)


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 18, 2009, 06:32:03 PM
 :) Little pocket camera I keep in the glovebox of the car. With the right exposure & preferably in focus, it'd be a nice atmospheric shot.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 19, 2009, 06:08:15 PM
PD nipped out to the local auto factors for me today & picked up new slave cylinders, shoes & a handbrake cable for the rear Sherpa van axle. He's a mechanic by trade so gets a bit of a discount. Having fitted both front discs & calipers, it's time to move onto the arse end brakes, then hopefully hook them up & get 'em working.


Title: Re: Manky's Pop.
Post by: ByzMax on September 19, 2009, 10:50:17 PM
Like that photo. you just need a welder going in the background. ;)

Must get down and have a look at this agian soon.

After I've been to see Shaun  ;D



Title: Re: Manky's Pop.
Post by: Manky Monkey on September 20, 2009, 08:12:34 AM
Yeah we'll stage the photo again properly when the car's finished.
There's a small back street car repair garage in Basingstoke, just up the road from my old flat. It's surrounded by modern buildings, but looks like it was built in the 50s, with a pair of tall wooden doors on rollers. I'd like to park the finished Pop half in & half out of the open doors & get some pics. With it's MMMotors logos on the doors & no modern stuff around it, it'd  make a great black & white shot.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 22, 2009, 08:13:05 PM
I nipped up to West Drayton this morning, (outskirts of London), & picked up a set of new wheel studs & chrome nuts for the rear wheels. I've used Speedshack several times before for that kinda thing & they've always been very helpful & prompt with mail order stuff. They're listed in our Links for Commercial Purposes section of the forum. Like a lot of people though, they've been hit by the recession & had to move out of their high street shop unit & are now operating from a tiny yard in the back streets behind the old premises. Still just as helpful though. Took me ages, driving round & round, till I found them, squeezed down a tiny alleyway. The rear axle on the pick-up used to live under a Sherpa van, so has 7/16" studs. I decided to swap them for 12mm ones, to match the front wheels, so was soon on my way back around the M25 with a bag of new studs & chrome nuts. I'll need to open the holes in the hubs out to 13mm to take the splined ends of the studs.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 22, 2009, 08:18:12 PM
One of the old wheel cylinders has been leaking, but I'm replacing them anyway. Took bloomin' ages to release the brake drums from their grip on the shoes. Eventually PD stepped in & beat them into submission with a club hammer. Job done. With the drums off & shoes removed, the drive shafts had to be pulled out so I can get the new wheel studs pressed into the hubs & also so the bearings & oil seals can be replaced. Right hand shaft no problem.


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 22, 2009, 08:21:17 PM
Left hand shaft ...bugger. Some damn fool built the workshop wall 2 inches too close to the car.
Knocking a hole in the wall is apparently not an option, so we'll have to shuffle the whole car over a couple of inches -not so easy now there's no rear wheels on it.


Title: Re: Manky's Pop.
Post by: poprodder on September 22, 2009, 11:01:39 PM
(http://i222.photobucket.com/albums/dd201/landlockedbjp/Laughing_Chimp.gif)

sorry could'nt resist.


Title: Re: Manky's Pop.
Post by: ByzMax on September 23, 2009, 06:22:04 AM
Good opportunity to narrow the rear axle.. ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2009, 09:06:08 AM
Or widen the workshop.
Just had a parcel from Triker Pete in the post. To pass the commercial SVA registration test, the pick-up bed needs to be longer than the internal length of the cab, (to stop people nailing a tea chest on the back of their car & claiming it's a pick-up). The internal length of the bed doesn't include anything fitted in it. We plan to use the original cylindrical Pop fuel tank, sat up behind the cab, so the bed length would be measured from the tank back to the tailgate, which would be too short to qualify. Simple solution is to fit a temporary tank slung under the chassis for the test, then change it afterwards, (perfectly acceptable). So I rescued the little square fuel tank from Taz's donor Reliant before TrikerPete took it away. He's just sent me the filler neck that was still attached to the bodywork, so we can try it all in place. Cheers Pete.


Title: Re: Manky's Pop.
Post by: panthershaun on September 23, 2009, 07:04:41 PM
I'm going to be running the original Pop tank fitted under the rear of the bed ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 23, 2009, 11:02:49 PM
We thought it looked too nice to hide out of sight -an oval cylinder -an ovaloid? Looks nicely vintage.
Had a big box of bits in the post today from Custom Chrome in Warwickshire. Not sure if that's the same Custom Chrome who do all the bolt-on bike accessories. Anyway, after spending months trying to find someone to make me a set of stainless steel exhaust headers for the Pop, with no success, I finally got fed up with being fobbed off by people who plainly don't need the work, & ordered a header kit. So we've got a big box of 45 & 90 degree bends, some flanges & a pair of collectors. All we have to do is weld it all together -simples!  :P


Title: Re: Manky's Pop.
Post by: panthershaun on September 24, 2009, 04:42:48 PM
-simples!  :P

thats lucky then  ;) :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 24, 2009, 05:49:35 PM
It looks so easy in the instructions!  :P
Drove over to Basingstoke this afternoon, (a 45 minute drive for me from Guildford), & picked up the 56mm socket PD had ordered for me from the local car spares place. We need one to undo the big hub nuts on the rear axle, so we can take the hubs off & press the new wheel studs in, then replace the bearings & seals behind the hub. Biggest socket I've ever owned! It's a very shallow nut & we couldn't get a grip on it with anything else. Standard size on Ford Transit hubs too apparently.
I also had my welder & gas bottle in the car. Loony's got a small roll of stainless MIG wire to tack-weld the headers together but it's too small to fit his welder, so I lugged mine out of the shed.
Just as I jumped back in the car with the socket, Loony texted to say he'd gone home with a migraine & wouldn't be at the workshop. Poo. So I had to turn around & head home again. Will probably be Saturday now before I get another chance to get over there.


Title: Re: Manky's Pop.
Post by: poprodder on September 24, 2009, 07:54:58 PM
stainless, thats shiny ain't it!!! :o ;)
 ;D ;D


Title: Re: Manky's Pop.
Post by: panthershaun on September 24, 2009, 08:34:34 PM
stainless, thats shiny ain't it!!! :o ;)
 ;D ;D

horrors  :o :o :o perish the thought  :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 24, 2009, 09:08:05 PM
Don't worry -won't be shiny by the time we've finished with it.  :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on September 26, 2009, 10:56:56 PM
Nothing very exciting to see at the moment, so no photos. Spent the afternoon at Loonyville, removing the back axle then attacking the hubs. The posh new socket I bought specially to undo the hub nuts didn't work -the nuts are very shallow & the socket's got a slight chamfer on the inside, just enough to nicely round off the corners. So we ended up beating them off with a hammer & chisel. We'll have to replace them the same way. They have tab washers which will stop them coming loose again. So now I need to find someone to press the old bearings out for me, then find a bearing supplier to replace them, then have them pressed back in, plus press in the new wheel studs. In the meantime the rear shock & 4 bar mounts can be fully welded as they're only tacked in place at the moment.
PD & Loony are also arranging the loan of a TIG welder to have a go at welding the headers up. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 01, 2009, 10:53:31 PM
Hmm. One small step forward, one giant leap back again.
Had the bearings pressed out by a local car repair shop. Drove across town to the bearing shop & ordered new ones. They're not a standard engineering size, which would be relatively cheap, they're a specialist auto size, which ain't. Over 40 quid each. We drilled the Imperial stud holes out to take the new Metric studs, (M12 x 1.5, same as the front wheels), then it was back to the car place to have the new bearings fitted.
I nipped back after work today to collect them. Slight problem. First one fitted fine. Second one started fine but as they pushed the bearing into the hub with their hydraulic press, the back face of the hub buckled. Obviously not designed to be under pressure. Bugger. So the hub's knackered. We're not actually sure if the back face runs against anything on the axle stub. If there's no direct contact it might be possible to machine off the damaged rim & make up a large spacer washer. First though I'm going to check the interfernet for Sherpa van spares people -no point spending lots on specialist machining if it's only a fiver for another hub.
Bugger, bugger, bugger.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 01, 2009, 10:54:14 PM
.


Title: Re: Manky's Pop.
Post by: cunningplan on October 02, 2009, 07:11:58 AM
Mankey, we have had the same problem with these sockets, with a angle grinder (flap wheel is best) we carefully grind the front face of the socket so it is flush (or even very slightly the other way) , it makes it fit the nut better.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 02, 2009, 10:00:53 AM
Yeah, thought of doing that, but the outside diameter is also too big to fit inside the hub recess, so I'd have to grind down the diameter too.


Title: Re: Manky's Pop.
Post by: terry t on October 02, 2009, 10:26:43 AM
hi manky shame about the hub.i think you will find the back part dose not touch the axle casing.its just acts as a deflecter to stop the dirt and dust getting in the bearing.when the hubs on the back plate should sit over it.but not touch.it may nead cleaning up a bit for the tapper part to clear axle casing.when they press the new bearing in it nead surporting on the solid part of hub (as you no now) check the ather on to see clearance


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 02, 2009, 10:47:00 AM
That's what I wondered Terry. I need to loosely re-assemble it all & have a look. There's a groove around the back face that looks like it should have a seal in it, but I don't remember there being one. It's an odd system, not like the Reliant axle at all. The end of the axle casing has a stub machined on it that the hub sits over & runs on, on the bearing. Then the drive shaft passes through the hub & is held to it with the wheel studs & a front covering plate. The bearing surface of the stub has a lip on the back edge so the hub can't slide further back, so I think the damaged back edge must just run against the brake back plate. I'll have another look when I'm back at the workshop in a couple of days, but will still check the 'net for cheap hubs just in case.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 09, 2009, 05:38:59 PM
Well, I've spent the last week ringing round loads of breakers yards, looking for replacement hubs, with no success, so we took another look at the old ones.
The damaged rim on the back of the hub doesn't actually contact anything. As Terry said, it just helps deflect muck from the back of the bearing & the oil seal. There's a pressed tin splash guard behind it, bolted to the brake back plate, which extends over the end of the hub & presumably catches any oil drips that might get past the oil seal, before they contaminate the brake shoes. With the rim cut off, the hub meets the splash guard but doesn't actually run inside it. After a bit of looking at it & measuring it, we decided it'd be fine.
Parted off & faced off on a lathe? Nope, hacksawn & hand filed. Job done.
The new wheel bearings are now fitted. Oil seals looked fine so I left them well alone. New M12 metric wheel studs knocked in & a good dollop of black Hammerite on them. Ready to fit.   


Title: Re: Manky's Pop.
Post by: panthershaun on October 09, 2009, 06:23:05 PM
cool  8) 8) back on mine this week ;D ;D I'm getting a bit behind now :'( :'( :'(


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 09, 2009, 06:43:23 PM
C'mon -we've got a date on the dirt oval at the Hayride next year mate.
Bumped into Kev Rooney, the SVA guru, at the Surrey Street Rodders' do the other week. He showed me his SVA compliant truck & we went through a few details. Sounds pretty straight forward.
I'm on holiday for 2 weeks now & desperately want to get some major work done on mine. Bet I don't though.


Title: Re: Manky's Pop.
Post by: ByzMax on October 09, 2009, 07:05:32 PM
I'm on holiday for 2 weeks now & desperately want to get some major work done on mine. Bet I don't though.

You should have the pop finished in two weeks  ;D

Come on Glass half full  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 09, 2009, 07:42:16 PM
 ;D Seem to have got bogged down in small detail stuff lately & not achieved much. Think we need to get a few big bits done to fire up our enthusiasm again.
*Paint brake back plates, then re-fit to axle & build up brake assemblies.
*Seam-weld all the suspension brackets that are just tack-welded at the moment, adding gussets & braces where necessary.
*Look at rear mudguard mounts, probably a variation of the bolt-on jobbies on my trike.
*Re-fit axle & adjust 4 bar linkages until it all sits square & true. Hook up the prop-shaft.
*Fettle brake pedal assembly to give more pedal travel, then look at hooking up the brake lines.
*Move to the front end & re-work steering stops to suit our steering lay-out.
*Add front mudguard mounts.
*Re-do the steering column mount. It's too big & industrial. needs something tidier. Also need to move it half an inch to the right to give more clearance between the linking rods & the side of the engine.
*Lay out & tack together the exhaust header components.
*Build a throttle pedal assembly.

With brakes, steering & suspension sorted, fire the sucker up again!  ;D


Title: Re: Manky's Pop.
Post by: poprodder on October 09, 2009, 08:36:36 PM
thats something i should do, make a list.


Title: Re: Manky's Pop.
Post by: Blackpig on October 09, 2009, 09:41:03 PM
That's your 1st week taken care of, where's the list for the 2nd week ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 09, 2009, 10:12:58 PM
 ;D In an ideal World I'd have all the necessary parts to do that lot & could do it in a couple of days.
In reality, I'll probably spend the first 3 days hacksawing & filing a couple of brackets, then re-doing them until they fit, then something will break, then there'll be some domestic errand or other to run that'll take up a few days
-before I know it, it'll be time to go back to work. Whole weeks & months have gone by like that so far.


Title: Re: Manky's Pop.
Post by: ByzMax on October 10, 2009, 09:26:31 AM
I'm suffering the same sort of problems at the moment. Every time I get in the workshop something comes up that I've got to deal with.


Had a very bad couple of weeks. Still positive though but taking a weekend off as it will help me cler my head.  ;)

Get stuck in and you will get more done than you expect.



Title: Re: Manky's Pop.
Post by: terry t on October 11, 2009, 11:09:27 PM
Hi Mankey.what can we cross of the job list then


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 12, 2009, 08:17:23 AM
Nothing yet. First day of my 2 weeks holiday today so I'm off to the workshop mid morning -it's a 45 minute commute away down the M3 & I've got some jobs to do at home first. Hope to get the back axle sorted today.
Maybe.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 12, 2009, 11:19:41 PM
Of course, things didn't go quite according to plan. They never do.
Tinkered in the shed at home for a while this morning, welding the exhaust for my trike, then meandered over to Loony's workshop in Basingstoke. I'd rung Bernie the sheet metal worker, who's making light housings for the indicators on the front mudgards. He works in Newbury, Berkshire, a half hour drive from Loony's place, so we drove over there to take a look at the lights as Bernie wanted my O.K on them before he went further.
Turns out his workshop was broken into over the weekend. The second time it's happened. He lost over 13 thousand quid's worth of sheet steel, aluminum & stainless. The gits had tried to break in at the back of the workshop by peeling the metal cladding off the wall. When that failed they tried to lever the fire escape door frame out of the brickwork. Then they had a go at the door itself. Not deterred, they then took an axe & cut a person sized hole through the front roller shutter door & opened the back door from inside. Then they opened a set of gates at the back of the building, ripped down a fence & drove a truck up to the door. They took an entire rack of welding rods, part made customers' jobs, all the off-cut metal that was laying around, even a stack of aluminium frames that belonged to Bernie's brother who runs an aluminium window & door frame business from the same workshop. The paint on the frames alone cost 2 1/2 grand. Most expensive loss was 2 sheets of bronze, specially ordered for a customer's job, at a thousand pounds a sheet. Bernie told us they even trashed the office where his Dad does all the company paperwork. He said it was heart breaking to see his 71 year old Dad on his hands & knees, picking up all the ripped up paperwork. Bastards.
And yet, my 2 little aluminium Pop front mudguards were left untouched, as was the computer in Bernie's office & the cash in his desk drawer. I felt a bit selfish asking him how he was getting on with them after that, but he was happy to show us.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 12, 2009, 11:24:32 PM
He's made 2 aluminium "Cornetto cones". He's pie-cut them along their length & pulled the cones round to follow the curve of the mudguards, then welded up the cuts -I think they look like big wiggly worms.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 12, 2009, 11:28:03 PM
Taz thinks we should leave the ribs cos they look quirky, but they'll be smoothed off & a flat base plate welded in. The bulb holders sit inside the cones & will bolt down through the guards to hold the whole assembly in place. The bulbs are orange cos they're indicators, but the lenses are frosted white glass, so they'll look like vintage side lights. The real side lights are incorporated in the headlights. The lenses are held with a small grub, (wiggly worm?), screw.
The whole lot will eventually be painted black. A lot of hotrodders try to hide the mudguards cos they'd rather not fit any at all, but I thought if we're going to fit them we might as well make a feature of them & have something with a bit of shape to it, rather than just a flat trailer guard.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 12, 2009, 11:35:23 PM
After hearing of Bernie's break in, I decided against asking him for any off-cuts of steel plate, so we went around the corner to BKI Welding, another very useful company I've blagged stuff from bought materials from a lot over the years.
We want to add some strengthening gussets to the 4 bar linkage mounts on the back axle. As well as making the brackets stronger, they'll also add some detailing to the underside of the pick-up. We only needed a couple of 6 inch off-cuts of 5mm plate. These are the templates we came up with.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 12, 2009, 11:38:36 PM
And this is the 10 feet of steel we bought! Well, it was cheap. 14 quid for 2, 5 feet long lengths. I'm sure we'll find a use for it somewhere.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 12, 2009, 11:42:12 PM
Loony then remembered that he's got the electricity board guys at his workshop tomorrow, repairing a supply fault, so he'll be without power most of the day.
So my task for tomorrow is to cut all the gussets in my shed at home & maybe drill some holes in them to make them more interesting, then get on with my trike exhaust.
Oh, the blurry thing in the back of the last pic is Taz's trike by the way.


Title: Re: Manky's Pop.
Post by: tbone on October 13, 2009, 07:46:16 AM
Bad news about the break in. You just know all its all gonna end up at the scrap yard  >:(


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 13, 2009, 08:48:59 AM
Yeah. If the scrapyards didn't turn a blind eye to where the stuff came from, it'd be a lot harder for these people to get rid of it, making it less attractive to them. Bernie's workshop's in the industrial estate -I think there's only one in Newbury, & although it's busy during the day, it's deserted at night -no security patrols or anything.
An interesting snippet of info from Bernie- he thought about fitting an infra-red alarm system. You can buy them now that are triggered by motion sensors to switch on a hidden infra-red camera when there's movement in the building. The alarm then texts your mobile phone to tell you & you can check the film on your PC or even your phone. Brilliant, though not much use if you're 50 miles away at the time. But he discovered through the wonders of the web, that burglars use mobile phone cameras or digital cameras to check for infra red signals. Apparently if you pan a digital camera around the room, then play it back, the beams show up.


Title: Re: Manky's Pop.
Post by: BikerGran on October 13, 2009, 12:01:35 PM
Still might get pics before they disabled it!

What a bugger.  Is there no alarm on the building at all?


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 13, 2009, 12:07:11 PM
Didn't ask Bobbi.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 13, 2009, 11:23:45 PM
Pile of little strengthening gussets for the suspension mounts on the rear axle now made.
They're actually slightly thicker than the mounts themselves but can't complain when the steel was cheap. I drilled a few holes in them just to make them more interesting. Loony has a bit of a thing for the holey look -a traditional 50s racing mod to save those all important few ounces of weight. If he had his way the entire car would be peppered with holes. When the axle's painted shiney black I might touch in the insides of the holes in red to tie in with the red detailing on the rest of the car when it's finished.
I've now decided the bodywork will be gloss black, rather than satin, cos it has a more vintage look to it. Most of the running gear will be powder-coated gloss black but the powder will have a different sheen to it than the painted body, giving a little contrast. Maybe.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 13, 2009, 11:29:18 PM
I bought a couple of rotorary Scotchbrite angle grinder pads the other day. Very handy for taking off surface rust without damaging the metal underneath. I tried one on these brackets & they came up like chrome, well nickel at least. So I had a go at the girder forks that FLC made for Taz's trike. The shed roof's leaked recently & the fork legs had got a little light rust on them. Good as new now.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 14, 2009, 12:58:38 AM
hmm nice wot size tyre is on th front of Taz's trike Andy? ive got a 200 on mine but that looks as wide for some reason :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 14, 2009, 09:56:11 AM
Hi Gareth.
It's the rear wheel from a Yamaha V Max. I'll check the tyre size for you. We need to fit a tyre that's marked as either "front" or "universal" to pass the MSVA test, so this is the old rear one, just to build the trike with. I'm told there's only one company that make a universal tyre in that size.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 14, 2009, 10:54:08 AM
It's a Metzeler 150/90/15 Gareth.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 14, 2009, 02:31:43 PM
ar righto :) the one ive got is a back tyre, let me know if u find out about any uni type tyres as i feel i may ave to use the same route to get mine through test and then put the rear one back on after as i dont know atm if my hiding the rotation details will be good enough not to be seen, thanks for the info :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 14, 2009, 10:12:19 PM
Loony welded the gussets to the axle today, carefully avoiding filling the holes with weld.
I think we're going with the Gothic, Victorian engineering look.  :) "Steam Punk" I'm told it's called. I reckon that look would really suit your truck trike VB.  ;)
I ordered some rubber flexible brake hoses from Rimmer Brothers, the Triumph spares company, for the front calipers yesterday. They arrived this morning. Too short. Bugger. So I nipped over to the local hydraulics shop & ordered some longer ones in braided stainless. Might pinch an idea from Odgie's "Shedster" project & sleeve them in rubber pipe to make them look more vintage.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 15, 2009, 12:51:20 PM
likes the looks on that Andy :) i may well get round to doing some steam punk stuff on the trike :)


Title: Re: Manky's Pop.
Post by: BikerGran on October 15, 2009, 12:57:28 PM
I like that
Quote
truck trike
!


Title: Re: Manky's Pop.
Post by: TwistedPatience on October 15, 2009, 04:21:43 PM
For true steampunk you need BRASS! ;D


Title: Re: Manky's Pop.
Post by: panthershaun on October 15, 2009, 06:47:01 PM
For true steampunk you need BRA'S! ;D

 :o :o :o :o you sure  :o :o :o





































 ;) :-*


Title: Re: Manky's Pop.
Post by: renegade53 on October 15, 2009, 06:56:34 PM
I ordered some rubber flexible brake hoses from Rimmer Brothers, the Triumph spares company, for the front calipers yesterday. They arrived this morning. Too short. Bugger.


i don't deal with them, wouldn't touch 'em with a barge pole. how come you went for rubber, why not braided aeroquip. i've got 'em on the pi, they're great.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 15, 2009, 08:24:30 PM
I guess you can only go on your own experience, but I bought the calipers from Rimmers & they were very helpful. All previous orders are kept on computer so when I rang them back & wanted the brake hoses, but wasn't sure which year of caliper I had, they immediately knew -apparently their computer phone logging system checked my phone number against their customer records & brought up all the previous orders on the operator's screen. Clever.
Went for rubber cos it's a 50s style truck with open front wheels -no arches or inner wings to hide the brake gubbins & I wanted a suitably period look. Rimmers sold rubber for about 7 quid each or braided for about 15.
Taz's trike is gradually heading more towards the steam punk look, rather than the tractor style we originally planned.


Title: Re: Manky's Pop.
Post by: panthershaun on October 15, 2009, 08:29:03 PM
but doesn't steam punk ruing those nice mohican's  :P :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 15, 2009, 08:41:57 PM
Hawkeye -last of the demi waves.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2009, 07:59:05 PM
Latest arrival at Loony's workshop. A nice old 60s Bedford truck, here for a drop of welding & a full respray, cab & chassis.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2009, 08:01:18 PM
A Loony & his lorry.

Gingerly turning it at the top of the yard & trying to park it in the barn without ramming it through the back wall.  :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2009, 08:11:30 PM
PD's been working on the little Honda chop & started putting together a tidy battery/electrics box. One small oversight -he hadn't allowed for the chain run. Bugger.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2009, 08:12:44 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2009, 08:47:00 PM
Back to the Pop.
With the neo-Victorian axle plates welded in place, I spent a couple of back-breaking hours with a hand file, de weld-spattering it all & clearing all the mounting holes. Loony's been inspired to create a little steam punkish copper breather tube, to replace the original Sherpa van plastic one -which melted away with the heat of the welder. We tapped a 10mm thread into the original breather hole, screwed a bolt in, cut the head off & welded the stub in place. The tube will eventually be silver soldered in place.  


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2009, 09:18:04 PM
With the axle back under the chassis, you can see how the triangulated 4 bar linkage rods slot into the mounts on the top.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 16, 2009, 09:33:09 PM
When we first started tinkering with the chassis rails, I cut an arc in the underside of the shock mount cross member & added in a curved section of 3mm plate, to mimic the curve of the diff casing. It now frames the holey plates rather nicely. Shame you'll have to crawl under the truck with a mirror on a stick to see it.


Title: Re: Manky's Pop.
Post by: spanners on October 16, 2009, 10:39:43 PM
mmmmm  youve got me thinking again (dangerous me thinking is)  i might just have to hot rot a 1980,s chevy truck mmmm ;) ;)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 17, 2009, 02:39:41 AM
thats looking right tidy mucka ;D


Title: Re: Manky's Pop.
Post by: ByzMax on October 17, 2009, 11:05:29 AM
That's really nice job that.  ;)



 


Title: Re: Manky's Pop.
Post by: trev on October 17, 2009, 11:11:58 AM
back to the bedford,its a TK me thinks,i used to drive one many moons ago,good little truck.


Title: Re: Manky's Pop.
Post by: spanners on October 17, 2009, 05:56:16 PM
there,s a t.k on evil bay  ,now, part restored all the hard works been done but its up in glasgow  and  i,ve been told i,m not allowed to buy it :( :( ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 17, 2009, 06:12:04 PM
Chuck a bucket of metalflake over it & slam it to the deck, roof-chop it & shove a supercharged big block motor in the back. N-i-c-e.
Actually, the engine's suprisingly small for a lorry.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 17, 2009, 08:00:52 PM
some one mention loory ;D sorry couldnt resist ;D


Title: Re: Manky's Pop.
Post by: spanners on October 17, 2009, 08:24:54 PM
hey  v.b there,s nowt wrong with lorry,s  /  trucks  i,ve got one as a daily driver  ;) ;) lol


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2009, 06:07:53 PM
As predicted, not much to report on the Popular front this week. Seem to have spent all my time running back & forth, collecting parts, so no photos to show you.
Loony's workshop is a 45 minute commute from home for me. One day this week I spent 2 hours sat in a traffic queue on my way there. The rest of the week I've been constantly driving around between Guildford in Surrey, Basingstoke in Hampshire & Newbury in Berkshire, sorting various parts out.
I've now got a roll of brake pipe & all the fittings I need except one, to make up the brake lines. That'll mean another trip to Newbury next week for the missing bit. Also got the use of Loony's pipe flaring & bending tools.
Bernie the metal worker, who's making the indicator housings for the front mudguards, promised they'd be done this week. Drove all the way to Newbury &, of course, they weren't. With luck I can collect them later next week too.
PD very kindly rebuilt the rear brake assemblies for me, despite having his arm in a cast after a wrist operation -thanks mate. Appreciate it. I couldn't get my head around the Sherpa van axle's self adjusting drum brake set-up. PD's a mechanic at a local garage so seemed silly not to make use of his expertise. The SVA requires at least the front brakes to be self adjusting, (taking up the slack when the pads/shoes start to wear down). The discs we've fitted up front will take care of that, but we've also got ratcheting rear drums, which will do the same at the back. When I bought new brake shoes & slave cylinders, I also picked up a new handbrake cable. It's the one piece type, with both brakes linked by a single cable, hooked up to a pulley on the bottom of the handbrake lever. We've got what we think is a Reliant lever, which has the pulley attached. With luck, it'll all work out just right to hook the Sherpa cable up to it & mount the lever between the seats on top of the gearbox tunnel, though it'll be tight for space. Would be nice to use a little bit of Reliant somewhere on this build!
Of course the brake cable didn't come with the E clips which hold the outer sleeve into the back of the brake drums, so I've spent an hour or so this afternoon driving around Basingstoke trying to buy a couple. Ended up having to buy a box of 300 assorted size ones from Halfords for 6 quid. Also had to find a sheet of gasket paper to make gaskets for the drive shaft/hub joints. Once the driveshafts are in & the drums are back on I can refit the wheels, then we can have a very careful measure up & get the rear axle properly centred & levelled in the chassis, using the adjustable 4 bar linkage.
Waited at home all morning today for a local welder/fabricator to ring & say he'd got some box section steel for me from his suppliers. Got the call after lunch to say it'd arrived -but he'd had to go out on a job. He's one of Taz's fellow Mopar muscle car owners, so we'll go & pick up the steel tomorrow morning & hopefully get a look at the car he's building too. The 25mm square, 2mm wall thickness box tubing is for the frame of the Pop's pick-up bed. Having had 2 weeks off work & not really achieving much, I just wanted to do something big that looks like we're making some progress. We'll build a framework that bolts to the chassis, rather than welding directly to it.
Late this afternoon Loony & I drove out to "Just Kampers", a local VW parts specialists, & picked up a pair of "bay window" camper van rear arch repair panels. They're about 4 feet long by about 2 feet tall & include the entire rear arch. If you flip back to somewhere near the start of this thread, you'll see pics of some we borrowed from a van repair job Loony did last year. I didn't want just a big square box on the back of the pick-up. I wanted something a bit curvier. The axle extends beyond the width of the pick-up bed & the rear wheels will be covered by "cycle" type guards, so we'll "cut n shut" the V Dub panels to shorten the arches down to a little wider than the axle. We'll still need to form the curve around the rear corners of the bed, but hopefully we can mimic the curves of the back of the cab. Looking at a camper van at the shop today, I wondered whether we could re-work a VW camper engine bay door to create a tailgate. Loony thought it'd be too much work to widen it but I might persevere with the idea as he's got an old one to play with. The inside of the box sides will be skinned with flat steel & we'll form a wide rolled top edge along either side using a couple of lengths of 2 inch bore ERW tubing.
To qualify as a pick-up for the commercial vehicle SVA registration we're aiming for, the pick-up bed interior has to be longer than the cab interior. It's a very basic rule of thumb, but easy to fall foul of. It refers to useable load space so anything in the bed will restrict that space. If we mount the original Pop fuel tank in the bed, up behind the cab as we intend to, the measurement is taken from the back of the tank to the tailgate -too short to qualify. So we'll use the Reliant tank from Taz's trike donor car, slung under the chassis, for the test, then change it afterwards, which is entirely permissable.
So we're getting there, slowly, but it does feel agonisingly slowly.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 23, 2009, 08:18:44 PM
jus read... sounds spot on on Andy you know where yer going with it and more important how ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 23, 2009, 09:49:27 PM
I do? I thought we were just making it up as we went along!  :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2009, 09:46:16 PM
Taz & I called at Paul the metal fabricator's place this morning & I picked up 20 metres of 25mm square box section steel. That'll form the framework of the pick-up bed. Paul's one of the old school Yank owners from the 70s & has run all sorts of muscle motors. Current project is a very clean '68 Dodge Dart. He's building a replica superstock racer. The Dart was basically the shopping car of it's day, (Paul's got the original bill of sale for his, made out to a lady called Ethel in New York state). Normal practice was to replace the bonnet, boot & doors with lightweight fibreglass copies, ditch the front bench in favour of lightweight van seats, chuck out the rear seat & tub the rear arches to take bigger rubber on a wider B body axle -oh, & shove in the biggest Hemi motor they could find. That's exactly what Paul's doing. Can't wait to see it running. "Don't look Ethel!"
Another hour spent sat in a traffic queue on the M3 today, heading to Loony's workshop. The first rain for a couple of weeks & people forget how to drive in it. Managed to turn off the motorway early so never found out the cause of the hold up. Hopefully nothing serious.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2009, 11:08:41 PM
When I eventually got to Loonyville, I spent an hour or two fitting the handbrake cable, (those little E clips are a bugger ain't they PD  ;) ), then tapping on the hubs & refitting the tab washers & locking rings. I then used my best Blue Peter paper & scissors skills to produce new gaskets between the hubs & drive shafts.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2009, 11:21:29 PM
Flushed with success, I moved on to re-fitting the drive shafts & brake drums.
Or would have done, if I'd realised the new, slightly larger wheel studs I fitted wouldn't fit the holes in the shafts & drums. Bugger. Loony didn't have a 12mm drill bit so I had to take them home to do. Fortunately the wheels fit O.K
Oh, & that bloody wall got in the way of the driveshaft again.  >:(


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2009, 11:40:30 PM
So we had a look at the VW panels. Decided we'll tuck the handbrake cables up into the front of the arches, so will narrow them down to roughly the width of the wheel. The pick-up sides will finish level with the swage line below the side windows, so we'll need to add a strip of sheet steel along the top of these panels. Bearing in mind the side panels extend down below the chassis, the pick-up bed will only be a foot or so deep -enough to safely carry a packet of sandwiches.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2009, 11:49:21 PM
I'd like the rear corners of the bed to curve around to the tailgate to match the back of the cab, so might have to pick up another pair of the Mini wings we used for that, which would quite neatly increase the bed length by a few inches to meet the SVA requirement.
The silencers leant against the wall are repro International tractor ones -hopefully quieter than the Cherry Bombs we've already tried.
Roof panel's the rear half of an old Rover P6 roof.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2009, 11:54:22 PM
The engine bay door of a split screen VW camper van. I reckon this'd work well as a pick-up tailgate.
Doesn't really show here, but there's a curved lip pressed into it above the number plate recess, that holds the number plate light.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 24, 2009, 11:56:20 PM
.


Title: Re: Manky's Pop.
Post by: poprodder on October 25, 2009, 09:28:51 AM
that bed is going to look the bo****ks.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 25, 2009, 10:26:31 AM
I do hope that's a compliment!
PantherShaun's building his Pop pick-up to be much more useable than mine. I think he's hoping to be able to carry a bike in the back. More like a "barn find" vintage farm truck.
Mine's much more a hotrod pick-up. I want it to look like an old 50s speed shop's shop truck. A "parts hauler", as if MMMotors was a real business, but with a Brit influence, (almost all the parts we've used are British, rather than just apeing American stuff). My pick-up bed's much more for show than serious use really, although we'd better make sure the tail gate's sturdy enough to sit on as everyone's bound to when it's parked up. With the oval cylindrical original Pop fuel tank mounted up behind the cab, load space will be down to a few square feet -but since when have hotrods been practical!  
Will be good to get the wheels back on & roll it outside to check the dimensions before we get too far with things. A bit awkward as it'll involve shuffling all the non running vehicles round outside, but worth it to be able to stand back & check it out from a distance.
I'd really hoped to have the brakes hooked up & exhaust headers made up by the end of my 2 week holiday. Back to work tomorrow.  :( Once that's done & we've figured out a throttle pedal assembly, we can fire it up & drive it round the yard. Cant wait!


Title: Re: Manky's Pop.
Post by: poprodder on October 25, 2009, 03:19:27 PM
sure was.  ;D


Title: Re: Manky's Pop.
Post by: Firery Fred on October 25, 2009, 09:44:29 PM
Getting there Andy,getting there  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 25, 2009, 11:22:45 PM
There's a lot more to building a car from scratch than you first think! We're learning a lot along the way though.


Title: Re: Manky's Pop.
Post by: Plasticpig on October 26, 2009, 10:13:10 AM
I like that picture. Thats how it should look.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on October 26, 2009, 01:56:53 PM
i love it ;D back end just looks soooo right mucka ;D brill idea using the vw bus stuff


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 26, 2009, 11:47:49 PM
Messrs PD & Lunatic aren't convinced by the VW back end -too much like a cut-down camper van. They'd prefer something more traditionally square cut. I'm a magnanimous Monkey though & I'm happy to be proved wrong. I'll wait until we've got the side panels hung from the framework & see how it looks.
Back to the plot.
Had a call at work this morning from Bernie the sheet metal worker. He'd finished the front indicator housings. So I trundled over to Berkshire when I finished my shift & picked 'em up. I'm very happy with them. May not look it, but there's an awful lot of work in those little cones. The white frosted lenses hide orange indicator bulbs. I think they're quirky & interesting. Details make all the difference. I could have bought something boring off the shelf, but why finish a one off, hand built vehicle with something mass produced.


Title: Re: Manky's Pop.
Post by: TwistedPatience on October 26, 2009, 11:51:14 PM
Those indicators are really nice, I mean REALLY NICE. ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 26, 2009, 11:53:31 PM
Why thank you Doc. Not my handiwork, just my idea.
The guards & their lights will be gloss black when they're finished.  


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 26, 2009, 11:57:23 PM
Flash, flash, flash.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 28, 2009, 09:33:24 AM
Bought a length of 15mm bore ERW tube yesterday so will have a play with the bender, (!), & see if I can produce 90 degree bends in it without crushing it. If so, I'll bend a couple & start looking at using them to mount the guards. The front ones will need to mount on the back of the hubs, so they turn with the wheels, but will need spacing out to clear the brakes & stuff.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 28, 2009, 09:50:19 AM
I slapped a coat of black smooth Hammerite on the rear axle hubs & drums, then fitted the off-side driveshaft & drum. The paint's still wet so couldn't push the drum all the way on, but looks tidy. We'll have to roll the car forward on the trolley jack before I can fit the near-side brake.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 28, 2009, 09:52:48 AM
Then I started cutting the box section for the pick-up bed. The vehicle registration rules say that to qualify as a commercial vehicle & pass the basic SVA test, the internal length of the bed must be longer than the internal length of the cab. A shorter bed looks much sportier, but won't pass, so we'll have to compromise a bit. There's nothing to stop us modifying it once it's been tested, but I don't think I'll want to start cutting it up again. Can't imagine anyone pulling us over & demanding to measure the truck, but with my luck they would, so better to keep to the regs I think.
The cab measures roughly 54 inches, from the footwell to the rear panel. So I cut a couple of lengths of box to 56. We'll start off with a basic flat rectangle that we can lay on the chassis & build up from there. The 56 inches is on the inside of the rectangle, so hopefully, even when we've added a sheet steel skin to the inside face, it'll still be an inch or so longer than the cab. The back wall of the cab might well get fitted with an internal skin to hide the framework underneath, which would knock a couple of inches off the cab measurement too.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 28, 2009, 10:13:11 AM
The framework overhangs the end of the chassis by about 6 inches & is about 3 inches wider either side. Internal bed measurements are 56 by 38 inches. When we originally laid out the chassis rails, we could only guess at the bed length. With 2 more bracing tubes running front to back, it should be plenty strong enough to support it's own weight -& hopefully that of a lardy Monkey sat on the tailgate. The front end needs to support the weight of the Pop fuel tank too.
With the rails laid in place, the bed suddenly looks enormous -we've been used to looking at the chassis & thinking that's the end of the vehicle. Final length will be about 4 inches longer than those VW side panels. Can't be any shorter so whatever we do. it has to stay at 56 inches. Curving the rear corners around to the tailgate would disguise the length a bit. With the back wheel propped in place, the distance from the front of the tyre to the front of the bed is roughly the same as from the back of the tyre to the back of the bed, so it looks in proportion. The front of the VW side panels will be extended down to meet the bottom of the cab, but we might cut the back a bit higher as I think it'll look sportier.
We know the chassis is perfectly flat, so next job is to clamp the rails to it & tack weld them into a nice flat frame to build up from.


Title: Re: Manky's Pop.
Post by: poprodder on October 28, 2009, 05:47:18 PM
excellent progress, and shiny paint!!!

is that a cedric in back ground?
cheers chris.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 28, 2009, 06:13:38 PM
Cedric? Crashy's Australian Mazda 1000.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 29, 2009, 04:45:20 PM
A small brainwave from Loony's Dad, who has an annoying habit of chipping in with brilliantly simple solutions to the problems we've been wrestling with for hours. Rather than worrying that the 25mm box section won't support the weight of the back end of the bed over-hanging the chassis, why not just extend the chassis another 6 inches. We've got offcuts of the chassis box section & can sleeve the joints to extend it out to the end of the bed. Simples.
No chance to do any more today, but will have a look at it tomorrow.


Title: Re: Manky's Pop.
Post by: renegade53 on October 29, 2009, 05:29:04 PM
looks like you're further along than panther


Title: Re: Manky's Pop.
Post by: panthershaun on October 29, 2009, 07:43:36 PM
 :P :P :P :P :P :P sod off  >:( >:( >:(  miles ahead of me  ::) ::) ::) ::) but I'll still whoop his ass at the Hayride next year  ;D ;D ;D ;D


Title: Re: Manky's Pop.
Post by: poprodder on October 29, 2009, 08:30:49 PM
:P :P :P :P :P :P sod off  >:( >:( >:(  miles ahead of me  ::) ::) ::) ::) but I'll still whoop his ass at the Hayride next year  ;D ;D ;D ;D


taz involved with this!!! :o :o :o ;D


Title: Re: Manky's Pop.
Post by: panthershaun on October 30, 2009, 06:23:32 PM
she'll be pushing  ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 30, 2009, 11:24:35 PM
She'll be slapping you if you're not careful!
I can whoop my own arse -erm, if you see what I mean.
Bring it on, Pants Shaun.  :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 30, 2009, 11:27:46 PM
Back to the story so far-
Having successfully bent a couple of 90 degree bends in the mudguard strut tubing, I churned out another half dozen this evening. Haven't used ERW tube this small before, so had to borrow PD's 1/2" former head for the hydraulic bender.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 30, 2009, 11:34:31 PM
Then I cut a pair of 4 inch chunks of the heavy gauge box section used for the chassis rails, cut them in half, narrowed them & welded them back together to form sleeves to fit inside the chassis ends. I drilled a couple of 12 inch long offcuts of box, tapped the sleeves into them & button welded through the holes to hold the sleeves in place.
Once the extensions are tapped into the open ends of the chassis rails I can seam weld the 2 sections together. That'll extend the back of the chassis to the length of the new pick-up bed framework.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 30, 2009, 11:36:13 PM
Another new arrival at Loony's Lair today. This cut down Suzuki Vitara's in for an external roll cage.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 30, 2009, 11:36:41 PM
.


Title: Re: Manky's Pop.
Post by: panthershaun on October 31, 2009, 09:24:54 AM
wish my Pop was living there  :'( :'( :'( all I get where mine is are geese


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 10:01:58 AM
Honk, honk!


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 07:45:01 PM
Another hour spent sat in a queue on the M3 today. Soul destroying just sitting there, staring at the back of the car in front, going nowhere. Even more annoying when you finally get going again & there's nothing at the front of the queue. It's always in the same place, between junction 4 & the Fleet services -I'm sure it's drivers just refusing to filter as people enter & leave the motorway. Muppets.
So a late start at Loony's shed of mechanical delights today.
First job was to shove a trolley jack under the back of the Pop & roll it forward so I could fit the other rear axle driveshaft. Paper gasket fitted over the hub, then driveshaft slid into place & held with a countersunk M6 bolt. Not used to axles like this. Instead of the hub attaching to the driveshaft & the whole assembly turning in a bearing in the end of the axle tube like the Reliant ones do, the hub turns on a bearing that sits on a stub machined on the end of the axle. Then the driveshaft passes through it & the end plate bolts to the face of the hub.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 07:46:17 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 07:55:04 PM
With the shoes given a quick scrub with some wet n dry to remove any glaze & grease, then the assembly squirted with brake cleaner, the hub was put back on & the wheels bolted on.
I now have Triumph Vitesse front hubs with disc brakes, adapted to take 15 inch diameter Hillman Minx wheels, with Sherpa van rear drums fitted with 16 inch old black taxi cab wheels. All 4 wheels now have new M12 wheel studs & chrome nuts. The back end's still up on axle stands at this point so a bit higher than it'll sit when it's finished.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 07:59:15 PM
Can't see it very well here, but the pick-up bed framework's laid on the back of the chassis. Doesn't look so long with the wheels on. We haven't tacked the rear corner of the cab on this side.


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 08:00:53 PM
Still got to adjust the 4 bar linkages to align the axle squarely in the chassis, then add some spacers to the bottom shock mounts.
The back of the chassis needs extending to the end of the new pick-up bed ...


Title: Re: Manky's Pop.
Post by: BikerGran on October 31, 2009, 08:10:51 PM
Another hour spent sat in a queue on the M3 today. Soul destroying just sitting there, staring at the back of the car in front, going nowhere.

So why keep doing it?  There are alternatives to the motorway you know!


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 08:19:22 PM
...with some 12 inch box section extensions. I made up a pair of sleeves from short lengths of the chassis tube, cut, shut & rewelded to fit snugly inside the box. The sleeves will be welded through the holes drilled in the side of the chassis, then the extensions checked for alignment & seam welded to the chassis ends. Then I'll cut a new rear cross member to close the end of the new, longer chassis.

Yeah, there's alternatives Bobbi, but they take me miles out of my way & the motorway's always clear when I get on it -doesn't get fouled up till about 5 miles later. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 08:25:13 PM
Off the axle stands & back down on the floor. Couldn't figure out why it wouldn't roll forward. D'oh! It's in "park". First time I've had the rear end hooked up to the gearbox & sat on the ground. I've got used to it being up on stands recently. Seems really low now! 54 inches to the highest point of the roof.


Title: Re: Manky's Pop.
Post by: NeilG on October 31, 2009, 09:41:07 PM
Lookin good



Now you've extended it Andy will it still fit in the garage  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on October 31, 2009, 11:01:12 PM
 ;D Haven't got a garage. We've got the use of a barn on the estate where Taz works, which is about the same size as Loony's workshop. Not sure how long we'll have that for though. There's a chance it may get requisitioned for estate use, which we can't really argue about. I fully intend to use the Pop as every day transport, not for the commute up & down the motorway to work, but for everything else, so it'll live outside most of the time.
Not building a squeaky clean show car here.  :)


Title: Re: Manky's Pop.
Post by: panthershaun on November 01, 2009, 08:44:41 AM
looking good mate  ;D ;D The bed doesn't look to bad, could fit a bike on that ;D ;D so for your next project you have to build a "Bobber" to ride in the back  ;D ;D ;D ;D ;) ;)


Title: Re: Manky's Pop.
Post by: BikerGran on November 01, 2009, 05:42:15 PM
Shaun did you mean his next project after the pop, and the trike, and Tazet's trike, and the Charger?

 ;)


Title: Re: Manky's Pop.
Post by: panthershaun on November 01, 2009, 06:58:32 PM
of course BG ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 02, 2009, 10:44:18 PM
The bed's only 56 inches long, maybe another 12 or so if you include the tailgate when it's down. Not long enough for a bike, even a short bobber -a Farthinger?
The other chassis extension tapped into place & both ends hacksawed off at 45 degrees.
The red wiggly bits are will be the mudguard struts.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 02, 2009, 10:56:03 PM
Another length of box cut to close the rear of the chassis. All cut at 45 degrees but deliberately slightly over length -the chassis tapers towards the front, so I'll fettle the joint to get it as tight & neat as I can. It's all just wedged in place here.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 02, 2009, 10:59:01 PM
Rear crumple zone. Yup, hit that & it'll crumple your car, no problem.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 02, 2009, 11:01:45 PM
So now the chassis reaches to the end of the pick-up bed.
Still just wedged in place here.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 02, 2009, 11:14:57 PM
Got to shuffle the chassis & bed cross members around a bit. Once the truck's been tested, we're going to mount the original Pop cylindrical fuel tank in the front of the bed, but will use an old Reliant tank, slung under the back end, for the test itself. If we can hook the 2 up together, we might keep 'em both for extra range. The spacings between the cross members aren't quite wide enough for the tank at the moment. Also got to sling a battery box under the bed somewhere. Both will sit behind the axle, clear of the suspension & prop shaft.


Title: Re: Manky's Pop.
Post by: Firery Fred on November 03, 2009, 07:23:12 PM
"crumple zone"  ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 03, 2009, 11:34:58 PM
 :)
Got absolutely drenched at work this morning -trudged round the streets delivering her Majesty's mail for 3 & a half hours in torrential rain. So was tempted to give the workshop a miss today & just go straight home. If I just do a little bit every day though, it'll eventually get done -won't it?
So it was nose to the grinding disc again.
First job, tweak the rear chassis extensions & rear cross member a bit then tack-weld them in position.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 03, 2009, 11:45:27 PM
The Reliant tank will sit here, but slung underneath the chassis. We'll cut off the original filler neck & plate it over, then weld a new neck in on the top face. As suggested by Loony, we'll use one of the small pop-up fuel caps, same as I've got on my trike -push down on the cap with your thumb, twist till it pops up, then unscrew. It'll be mounted in the rear corner of the pick-up bed floor. I'd like to keep the Reliant tank once the truck's been tested & hook it up in tandem with the Pop one, but not entirely sure how that'd work.
Anyway, the chassis cross member between the axle & the rear of the frame was too close to the back end to allow fitment of the tank, so once I'd tacked the rear piece in place, I chopped it out with the angle grinder & cleaned off the welds.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 03, 2009, 11:52:00 PM
Because it'd been cut out, it was then about 10mm too short to weld back in. So I made up a sleeve to fit in each end to bridge the gap between cross member & chassis. A little careful measuring & it was welded back in, in the right place. The gap behind the cross member's now big enough for the tank to fit in, (remember it'll be under the bed, flush with the top of the chassis), & the gap in front of it's big enough to drop the battery into. I'll make up a battery box to either bolt or weld into the chassis, with an access hatch in the bed floor. The bed sides & tailgate panel will extend low enough to hide all this.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 03, 2009, 11:57:40 PM
With the bed framework laid back in place on top of the chassis, I can now cut & tack in various cross members to provide a floor strong enough to support people sitting in the back at shows.  :) Obviously I can't run any cross members over the top of the battery or I won't be able to lift it in & out.


Title: Re: Manky's Pop.
Post by: poprodder on November 04, 2009, 06:29:32 PM
excellent progress.
i've had 2 days(8hrs a time) of being soaked through(even money in me wallet was wet!!!)


Title: Re: Manky's Pop.
Post by: spanners on November 04, 2009, 09:20:01 PM
excellent progress.
i've had 2 days(8hrs a time) of being soaked through(even money in me wallet was wet!!!)

bloody hell,,,,,,,,,,,,,,,,,,,,,,,,,,, mug him  he,s got money in his wallet !!!!!! :D :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2009, 10:08:35 PM
If you put the notes in your tumble dryer to dry out would it be money laundering?
Had a puncture on my daily commuter car a day or two ago, which turned out to be a dented wheel rim. Took it to a local refurbishment company yesterday afternoon, who straightened it out -well rounded it out anyway. Collected it after work this afternoon. 30 quid. Good service & cheap too -assuming it stays inflated. Valuable Pop building time was lost in collecting the wheel & refitting it today. Oh, & I got rained on again.
So today's workshop visit was reduced to digging the Pop fuel tank out of the spares pile & trying it in place, before deciding on the position of the pick-up bed cross members & starting to cut them.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 04, 2009, 10:15:45 PM
In a standard "sit up & beg" Ford Pop, the tank lays horizontally under the boot floor, with the long filler neck extending up to the rear bodywork. We plan to stand ours on edge, supported in a stylish but sturdy cradle bolted to the pick-up bed. The filler neck will be cut off & blanked off & a "Monza" style flip up cap fitted to the top edge. The fuel gauge sender unit & fuel line feed will also be moved.
I'll add equally spaced cross members across the bed, plus a couple going the other way, spaced for the feet of the tank cradle to sit on.  


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 05, 2009, 01:06:22 AM
thats looking kewl mucka ;D


Title: Re: Manky's Pop.
Post by: BikerGran on November 05, 2009, 02:35:52 AM
Quote
Obviously I can't run any cross members over the top of the battery or I won't be able to lift it in & out.

Wish someone had had that thought when they rebuilt my mini trike....................

 :-\


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 05, 2009, 09:29:55 AM
Oops!


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 06, 2009, 08:05:21 PM
Another fleeting visit to the workshop tonight. Loony & I cut another cross member then tacked them all in place, equi-distantly, (good word huh). As the rear tank will hang below the bed, we'll probably end up adding another cross member in above it. We plan to use a ribbed steel sheet, available from the local auto factors, for the bed floor. With the raised ribs running the opposite way to the cross members, it should make it all good 'n' strong.
Tomorrow we'll start on the sides.


Title: Re: Manky's Pop.
Post by: panthershaun on November 06, 2009, 08:32:20 PM
I'm envious mate, work and other things slowing me down at the moment >:( may need to take some time off soon  ;) ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 06, 2009, 10:08:09 PM
Yeah, work gets in the way of the rest of your life don't it!
The Post Office strike planned for today was called off at the last minute last night -Taz & I learnt of it from the TV news while we were sat in the local BurgerKing. It was our day off yesterday so if Taz could've got today off work we might have gone away somewhere for a night. Good job we didn't. 4 of our Posties obviously don't watch the news, so will get docked a day's pay. Could've done with spending the day working on the truck. Can't wait to get the side panel framework together & maybe roll it outside for a better look.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 07, 2009, 07:38:35 PM
One of the 4 Posties who didn't turn in for work on the proposed strike day yesterday is now in hospital. No, not heavy handed management. Someone went to his house to tell him the strike had been called off & found him slumped unconscious at the bottom of his stairs. He lives on his own, so if the strike had gone ahead, probably wouldn't have been found till today. Haven't heard what was wrong with him yet. Weird how fate works sometimes ain't it.
Another busy day at work, clearing the backlog of mail. Almost back to normal again now. So just a couple of hours at LoonyLand this afternoon.
When I started on Taz's trike project I bought a pile of ERW tubing in various sizes, including 10 feet of 2 inch bore. Only needed a few inches for the axle clamps but they wouldn't sell me less than 10 feet! It was chopped roughly in half to fit in the back of my car, then a length big enough for her clamps cut off. I want to create a radiused top edge to the pick-up bed, so I dragged it out from the scrap pile today. Perfect diameter, but unfortunately one half was too long & the other too short.
So I spent my couple of workshop hours today cutting the long one to size, then using the off-cut to extend the short one. As is my usual practice, I spliced the 2 tubes together using a sleeve made from a length of the same pipe, sliced down it's length & squeezed in the vice until it's a tight push fit inside the tube ends. In this instance there's no joint strength required, but the sleeve helps to keep the 2 sections nice & straight & true. I drilled through the outer tube into the sleeve, then button welded the 2 together to stop the sleeve moving inside the tube. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 07, 2009, 07:43:36 PM
Tapped the 2 sections together with a big mallet, leaving a gap to weld in, (about 5mm). I also drilled the other half of tube & welded through it into the sleeve.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 07, 2009, 07:47:38 PM
Finally I welded the joint, a little at a time, moving from one side of the tube to the other , rather than one continous weld, to minimise heat distortion. Unlikely, given the thickness of the tube & length of sleeve, but good practice anyway. Then I ground it almost flush & finished off with a hand file. All that work & no-one will even notice -but then, that's the idea.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 07, 2009, 07:59:18 PM
Once I've cut & welded the box section side uprights in place, the tubes will lay along the top of them to create a rolled edge. They'll sit at the same height as the swage line on the doors, (same height as the panel joint under the back window). This is a very common design for custom pick-up sides, but works well I think. Also quite traditional is mounting round lights in the ends of the tubes, but which ones? The running lights or indicators? Or neither? Loony suggested pointy Cadillac tail lights, but I don't think they'd suit the truck's style. It's a Brit rod so should use British parts. Besides, I've already bought some round, fairly flat light units, as shown previously in this thread.
PD's well over 6 feet tall, but with him stood alongside the Pop, you can see just how low it is.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 07, 2009, 10:03:32 PM
Um wot about having stop/tail light in the tube ends, and then the indicators in cones same as front but on tha back ? only an idea


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 08, 2009, 09:43:00 AM
Yeah, did think about that Gareth, but it took 3 months for Bernie to get round to making the front ones!
Might end up keeping it simple & just mounting them in the bottom corners of the panel under the tailgate. They should be within 400mm of the outside edge of the vehicle, so got to be fairly close to the edge of the bodywork cos it doesn't extend out as far as the tyres.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 08, 2009, 03:11:30 PM
aye fair enough Andy i got a similar issue "light placement" or will ave with my trike :)


Title: Re: Manky's Pop.
Post by: spanners on November 08, 2009, 04:59:36 PM
aye fair enough Andy i got a similar issue "light placement" or will ave with my trike :)




ive just spent the afternoon on the same job    ,bl,,dy tail, lights  still undecided  :-\ :-\


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 08, 2009, 05:31:50 PM
Don't forget to check they fall within the required measurents for the MSVA test. I've mounted my trike rear lights on the back of the axle clamps, but will have to temporarily raise them for the test as the indicators are too low.
The positions for trike lights are stickied at the top of the Trike Tech section.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 08, 2009, 06:03:26 PM
Don't forget to check they fall within the required measurents for the MSVA test. I've mounted my trike rear lights on the back of the axle clamps, but will have to temporarily raise them for the test as the indicators are too low.
The positions for trike lights are stickied at the top of the Trike Tech section.
yup ive got and printed out ;D i think i'll be ok just the tyres are 275 wide and my back lights are like yours, back end is 4ft4 wide with the tyres ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 10, 2009, 06:21:41 PM
Another brief visit to the workshop today. I'd spent all morning trudging round the streets delivering the mail in the rain & was cold & wet, so took a while to get myself into a workshop frame of mind. Loony had to leave early though, so I contented myself with tinkering with the pick-up top tubes again for an hour or so. Finished tidying up the welded joint from the other day, then cut a pair of 3mm discs, (cut from the 45 degree offcuts from the end of the chassis -waste not, want not). I then welded these to the ends of the tubes to blank them off. This'll be the cab end of the tubes as I'm still undecided about mounting lights in the other end. If I decide not to, they'll be blanked in the same way.
Weldy, weldy, flap wheely, flappy, filey filey. Done.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 10, 2009, 06:33:13 PM
While I was doing that, Loony pinched the engine bay door off Doug's VW camper van. He's still not convinced about it -not keen on having a big bright yellow number plate in the middle of it & would rather tuck it away under the tailgate somewhere. Personally the number plate thing doesn't bother me but I can see what he means -it's a necessary evil & I think it's more of a challenge to make it look good though. I'd like the pick-up panels to be a bit more interesting than just a flat sided box.
Because the bed won't be as tall as the VW door, it would have to hinge from lower down, below the chassis. That might give me a chance to add a hidden storage box for tools etc, under the fuel tank & accessed by opening the tailgate.
Here my beautiful photographic assistant holds it in place.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 10, 2009, 06:38:56 PM
Loony's been busy spraying a car today -a Saab, & his mate Doug's been repairing a car, while I've been messing with Pop stuff, so we had 2 MIG welders & a compressor running in the workshop. Very noisy.
Loony & PD have taken on the job of knocking up an external roll cage for a local off-roader. They've started by welding huge box section "rock sliders" direct to the chassis below the doors. They'll then build a tubular cage up from there.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 11:56:57 AM
Back to the plot again...
Had a torrential rain storm the night before last which ended in a power cut so couldn't get online, then last night I was so knackered by the time I got home from a day's work, followed by an evening's workshopping, that I went straight to bed.
So I haven't posted any progress for 2 days, so-

First off, I spent an afternoon cutting & drilling 5mm steel mounting tabs to fit the pick up bed to the chassis, then welding 4 of them along each side.   


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 12:02:09 PM
Then I cut & fitted corresponding 3mm tabs for the bed frame, (the square box section of the bed is between 2 & 3mm wall thickness, whereas the chassis is heavier gauge).


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 12:12:10 PM
M8 stainless bolts dropped through the holes. Suprisingly, they all lined up. Originally we'd planned to leave them as normal nuts n bolts, but access will be limited once the pick-up bed floor's welded in, so we welded the bolt heads to the mounting tabs to form captive studs. The weight of the bed is laying directly on the chassis, so the tabs just locate it. Bolted down, we now have a flat, level platform to build up from. Not sure if the commercial SVA registration test we're going for allows flat bed trucks, but I quite like it like this. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 12:41:16 PM
We've been wondering about the rear suspension travel for a while. Those top triangulated arms run quite close to the underside of the bed. So we went for worst case scenario. The rear coil over shocks are something like 160 pound rated I think. We haven't altered the spring settings since we fitted them, but they have a dial on the bottom to adjust the oil damping. With that set to it's lightest boinginess rating, (technical term), & 14 stone of Lunatic jumping up & down on the back of the chassis like a mad jumpy thing we could just make contact between the arms & bed frame. Clang. Better sort that then.
Chopped out the middle of the cross member & added in a couple of bits of box to follow the angle of the arms. I was going to cut the next cross member too, but that would leave a big area of floor unsupported as well as the fuel tank we plan to fit in the front of the bed &, as Loony pointed out, if the front of the arms came up that high, the axle would be smacking against the chassis & we'd have bigger problems to worry about.   


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 12:55:37 PM
We re-did the Loony Boinginess Test. Sorted.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 01:10:47 PM
Then there's a bit of a jump as things went together quite fast.
Yesterday I started by cutting 8 box section uprights, 4 for each side of the bed. I scalloped the tops to take the 2 inch bore top tubes so that they're flush with the inside face of the uprights & overhang the outside. Including the tubes, the bed is 12 inches deep. With those all tacked in place, we added the top tubes, plus a horizontal length of box across the front, below the cab rear window. Rather than sitting that level with the top of the tubes, we put it level with the bottom of them, just to give the bed a bit more shape.
As I said, things jumped on a bit here, as we got carried away & started mocking up the next few bits. This is the original Ford Pop fuel tank, that normally sits under the boot floor of the car. We plan to mount it upright like this in a cradle bolted to the bed floor & backed up by the second Reliant tank hidden under the back of the bed. As we've said before, the SVA registration test requires the pick-up bed to be longer than the cab. Anything fitted in the bed will be subtracted from it's length, so we need to leave this tank out until after the test.
The Pop tank will end up level with the top of the bed sides & we'll shorten the filler neck down & "pie cut" it along it's length, pull it round in a curve & re-weld it so it's vertical. It'll have to be slightly taller than the tank so we can fill it to the top. The fuel outlet & sender unit will also need to be relocated. I could buy a spun aluminium "Moon" tank but I like the idea of recycling parts of the original car.
I've also added another cross member over the rear tank -the tank will be below the floor level & if anyone's going to sit on the tail of the bed, that's the area they'll be sat on, so we needed some extra arse support.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 01:25:06 PM
Suddenly it looks like a proper pick-up truck. Nothing like the saloon car we started with.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 01:35:45 PM
Spurred on, we dug out the VW camper van repair panels I bought recently & clamped one in place. Loony's been unsure about these since we got 'em, but once in place, they look spot on. Just enough shape to them to be interesting, without being over fussy. They'll extend down to meet the bottom of the cab at the front & we'll cut a bit of a curve at the back to come up & meet a valance panel under the tail gate. The bottom edge of the V Dub panels curves inwards rather than being completely flat & slab sided. We'll need to extend the front by about 8 inches to meet the cab but Loony reckons that should be fairly easy to do. We also need to cut n shut the panels to reduce the arch opening. The top of the arch will be level with the underside of the chassis.
You can see here how the top tubes "roll over" the top of the panels, overhanging them. Just makes it all a bit more shapely.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 01:48:28 PM
The rear axle's several inches wider than the front. On other styles of truck, the rear wheels would be covered by arches attached to the bed itself or tucked under the bed sides, but we're going for these small cycle type guards. I think they accentuate the tall skinny 50s truck tyres & make the bed look lower.
We've decided to mount the rear indicators in the ends of the top tubes & site the stop/tail lights in the corners of the valance panel under the tail gate. Indicators should be visible from 45 degrees from the back of the vehicle so that should be fine. We also need to fit reflectors & fog & reversing lights, all of which will probably go in that valance. Loony had to admit I was right about the V Dub side panels & I admit he was right about the tail gate. We'll make our own in sheet steel & set a long regular sized numberplate into the valance panel.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 01:51:38 PM
The inside face of the bed will be skinned in flat steel sheet & the bed floor will be made in pressed ribbed sheet with the ribs running from front to back. That'll be stronger than flat sheet & look more interesting & more truck like. We may have to add sound deadening sheet to the space between the 2 skins, or even inject expanding foam, to stop the panels "drumming".


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 01:59:54 PM
So that's us up to date. This is my favourite view of it -apart from the view through the screen as I cruise down the road in it of course.  8)
I'm really pleased with the lines of the thing now. The nose has been stretched, with the front beam axle pushed several inches further forward than standard, & the back has been extended beyond the original Pop's length, but it still looks in proportion. The stainless exhaust headers will fill the space between front wheels & cab. The extra inches in the wheel base also make the 3 inch roof chop look lower & the pick-up bed looks like an integral part of the vehicle design, not just an after thought plonked on the back.
As soon as we get a dry day I'd like to roll it outside & stand back & take a good look at it.
Can't wait to fire it up now! 


Title: Re: Manky's Pop.
Post by: BikerGran on November 15, 2009, 03:36:50 PM
That's beginningb to look rather special!  Bet you are starting to believe it may be finished one day... :)


Title: Re: Manky's Pop.
Post by: poprodder on November 15, 2009, 04:05:54 PM
hi,
lots of excellent work there, looking real good.
chris.


Title: Re: Manky's Pop.
Post by: gazzagood on November 15, 2009, 08:04:39 PM
Andy looking great mate. ;D. just a thought. but you say you want ribbed sheeting on the base.. then foam fill. well some new buildings.have 25mm foam filled rib panels.on the roof.only trying to help  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 08:34:53 PM
Worth a look. Got to be mild steel so it's strong enough to stand on & so we can weld it though, which would mean stripping the foam out of the edge ribs so it didn't burst into flames. Unless we could find a way of fitting the base without welding -maybe just mastic it down? I was thinking more of the 1 inch gap between inner & outer side panels.


Title: Re: Manky's Pop.
Post by: spanners on November 15, 2009, 08:42:15 PM
looking good ,,,,,,,,,,,,,,,,,,,,,just a thought when assembling youre ,double, skin side panels          there,s an aerosol weld through spay paint/coating that you can treat the area wher the skins/panels join that you weld through and it doesnt burn away but protects the seam so that it doesnt rust and ,bleed through at a later date i used to use it when fitting/welding in 12/14 metre long ,stretch panels on the side,s of coache,s

                            just a tip/thought
                                             mike


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 15, 2009, 08:50:28 PM
The guys rebuilding Taz's Dodge Charger use a zinc spray like that. I think Loony's actually got a can somewhere in the workshop. Yup, well worth doing Mike.


Title: Re: Manky's Pop.
Post by: spanners on November 15, 2009, 09:02:11 PM
just wish i was still at work at boydons i kept a box of the spray cans under my bench


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 16, 2009, 09:56:15 PM
Called at Loony Central again after work today, but Mr L had other plans for the afternoon. So I just quickly tried my rear lights in place. Thanks to the magic of masking tape, here's the amber indicator sat in the end of the top tube, plus the red stop/tail light down in the bottom corner of what will be the rear valance panel. The indicator's slightly bigger than the tube diameter, so I'll have to make a large flat washer for it to sit against on the tube end. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 16, 2009, 10:17:49 PM
Meanwhile, PD & Loony have been messin' with the mudster, bending up a 2 inch bore tube to loop over the cab, from one rock slider to the other. Now they're adding tubes from the cab to the rear cross member. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 18, 2009, 11:52:28 PM
By the time I finish work & get over to Loony's place, I only get a couple of hours to work on the Pop before I have to do battle on the motorway back home again. So today's task was to knock up a frame for the tail gate. Cut from the same 25mm box section as the rest of the bed, it stands at 10 1/2 inches tall.
Would've been nice to re-use the hinges from the original Pop bootlid, but unfortunately we scrapped it when we cut the car up. Loony's got an old Mini sat outside his workshop -the boot hinges from something like that would work but I can't decide whether they should be hidden or surface mounted. I'd like to fit the rear door latch from the Sherpa van the axle came from, but I binned it a month or two ago. Bugger. The back doors of a Sherpa van have a handle on the inside that pushes bars up & down to lock the door into the frame. I'd like to fit a T handle on the inside of the tail gate, with bars locking into either side of the pick-up frame. Same way a garage door lock works. Anyone got anything suitable?   
Not even finished yet & it's carrying it's first cargo already. Skeleton pick-up bed provides somewhere to stash some of the other Pop parts.


Title: Re: Manky's Pop.
Post by: brock on November 19, 2009, 12:39:37 AM
http://www.garage-door-spares.co.uk/spare-handles.htm

how much like a garage door system ? cardale do a nice pop up handle, locking, and could be used on the outside


Title: Re: Manky's Pop.
Post by: spanners on November 19, 2009, 01:20:37 AM
how desperate are you for a tailgate locking mechanism  as i,v got my chevy up the yard the tailgate locks with a central lift type handle that pulls two slide catch,s    i was thinkin on ditchin/scrappin/sellin the rear body in favour of a flat or ,,stake side,,   some of it maybe of some use to you


p.s  still havnt got a starter motor for it  (maybe brock?????)


Title: Re: Manky's Pop.
Post by: panthershaun on November 19, 2009, 01:31:31 PM
exposed boot hinges Manky, match the doors  8) 8) 8)


Title: Re: Manky's Pop.
Post by: afghanman on November 19, 2009, 06:50:15 PM
Is the mechanism going to be on the inside or out? cos I have a cunning plan ;)k


Title: Re: Manky's Pop.
Post by: tbone on November 19, 2009, 07:00:38 PM
I`d go for hidden hinges, but what do i know? oh i do know one thing.........NEVER throw anything away!  ;D


Title: Re: Manky's Pop.
Post by: afghanman on November 19, 2009, 07:14:58 PM
"Doh" just re read your post. inside ,,,,,my plan will still work though!


Title: Re: Manky's Pop.
Post by: panthershaun on November 19, 2009, 07:20:44 PM
Gotta be exposed hinges, if you start hiding things the next step is ultra smooth streetrod  :o :o :o and I would still like to talk to Manky at shows  ;) ;) ;) :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2009, 07:30:49 PM
Too many questions!
The tail gate frame's only 25mm wide. It'll be skinned front & back in flat steel sheet, then I have some raised lettering to add to the outside, which is why I want the handle on the inside. Will also just look tidier I think. No need for it to lock really -what's it going to protect? but might stop it accidentally popping open while I'm driving I guess.
So whatever I use has to fit inside a 25mm gap, or I'll have to fabricate a surface mounted box for the internal gubbins to fit in. Mr Brock's suggestion will do the job admirably, but I'm open to suggestions, cunning or otherwise.
TB, I kept the Sherpa lock for about 2 years, then binned it cos I couldn't forsee any reason for ever needing it. D'oh!
Minis have stubby, chrome, surface mount hinges that extend up the boot lid a couple of inches. Hidden or surface -still can't decide, but it definitely ain't a high tech cruiser! Will you stil talk to me when I whup yo' ass in it at the Hayride next year Shaun?  :D
Also need support struts or chains to hold it in the open position. I'd prefer some sort of folding strut, rather than a dangling chain, but, again, open to suggestions.
Mike, how bulky is the Chevy lock mechanism?


Title: Re: Manky's Pop.
Post by: afghanman on November 19, 2009, 07:35:20 PM
This might work? maybe a bit steampunket?

Old style French windows have a closing handle that operates two bars so that when the handle is turned the bars locate into the fittings at the top and bottom of the frame.

I have about a million of them  ::)

(http://i171.photobucket.com/albums/u284/afghanman_photos/IMGP0588.jpg)

(http://i171.photobucket.com/albums/u284/afghanman_photos/IMGP0589.jpg)


Title: Re: Manky's Pop.
Post by: TwistedPatience on November 19, 2009, 07:41:13 PM
Nowt wrong wiv Steampunk ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2009, 07:42:40 PM
Now that's interesting. Brass? Not sure the curtains would match though.


Title: Re: Manky's Pop.
Post by: afghanman on November 19, 2009, 07:48:00 PM
They range from fancy cast iron ,alluminum or pressed steel. the later ones are a bit more angular in a kind of "Deco" thirtys style.


Title: Re: Manky's Pop.
Post by: lunatic on November 19, 2009, 08:01:59 PM
Now that would be cool!
Oh yeah, exposed hinges, definately!


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2009, 09:41:07 PM
Hmm, the Loony one has spoken.  :)
Looks like the paint would soon get rubbed off the locking rods, leading to streaks of rust down the tail gate. We could make new rods in stainless steel I suppose, but that would kinda defeat the object of using something with a bit of history to it. Polished ali would work though.
Any chance of a piccie of your aluminium ones Sir?


Title: Re: Manky's Pop.
Post by: afghanman on November 19, 2009, 09:47:27 PM
It might be possible to mount the handle on the frame and pass the locking rods inside the top tube?

Have a look for you tommorow, am coming over on saturday I will bring anything I think suitable and leave with Shaun.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2009, 10:10:36 PM
Yeah, depends how big the handle bit is really.
You're visiting our fair isle? Welcome back Sir. Would appreciate a big bag of interesting stuff  :) Thank you. I'll sort out the cash for it with you later if that's O.K


Title: Re: Manky's Pop.
Post by: voodoo on November 19, 2009, 11:04:36 PM
You could always polish them up and then stick a coat or two of clear lacquer on them...then no rust problems...Voodoo...


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 19, 2009, 11:18:35 PM
True.


Title: Re: Manky's Pop.
Post by: afghanman on November 20, 2009, 05:18:49 PM
A couple of pics for you, should be clear how the thing works,
You are welcome to these, Owe me a beer if we ever meet up  8)
(http://i171.photobucket.com/albums/u284/afghanman_photos/bikes/IMGP0591.jpg)
(http://i171.photobucket.com/albums/u284/afghanman_photos/bikes/IMGP0593.jpg)
They maybe wont suit your build but they could look quite cool and "Old school".


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 09:04:07 PM
We'll cetainly have a play with them & see what they look like in place. Thank you Paul. Very much appreciated.  ;)
I know beggars can't be choosers, but I like the top one. Have you got a matching pair of the top left end fittings?
Hoping Mr Shaun will come see us at Loony's workshop soon to compare Pop building notes, so maybe he could courier them up to Basingstokeshire for me.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 09:25:47 PM
No workshopping again today as it's Loony senior's birthday -happy birthday Dave, (Loony's Dad & owner/co builder of Physcho Triko, the V Dub trike in the Motors, 3 wheels bit of the site). So Loony had more important things to do.
Which left me to trundle back & forth between various suppliers, picking up bits & pieces for the build.
First I nipped over to Tadley in Hants to collect some marker lights for Spanners' trike. They'll be on their way as soon as you PM me your current address mate.  ;)


Title: Re: Manky's Pop.
Post by: afghanman on November 20, 2009, 09:30:46 PM
 :-[Ooops  didn't notice I'd picked up an odd pair ::)
If you want to use that one, I will send you the right bits when I get back from England.

Sorry just realized that I am going to be next door to you! staying in Farnham.
I am leaving here tomorow early. Can you pm me your phone number? tout suite?


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 09:37:09 PM
Then I picked up a power socket for my trike. Been meaning to fit one for a while. Always useful for powering ...err powered stuff. Torches, tyre inflators, phone chargers. Whatever. I'll fit it in the side of my battery box.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 09:39:31 PM
PM sent Paul.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 09:43:12 PM
Then I found myself a pair of red reflectors for the back of the Pop. Nice chromed surrounds & proper glass lenses -none of yer modern plastic rubbish. About 3 1/2 inches long. Might mount them vertically down either side of the tailgate. Or across the bottom of it. Can't decide yet.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 09:47:33 PM
Some big fat washers to weld to the ends of the pick-up bed top tubes. Same diameter as the indicators so should work nicely once they're blended in to the tubes.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 09:58:24 PM
Finally off to the Aladin's Cave that is the local trailer parts shop in Micheldever, just outside Winchester. This place is wonderful -full of all sorts of lights, reflectors, clips, hooks, wheels, mudguards etc -all very useful stuff. Rather scarily, the guy remembered me & asked how my trike build's going -I haven't been in there for 2 years. And no, I haven't finished the trike yet.
I needed a set of hinges for the tailgate. Could've used cheap old garden gate hinges from B & Q. Or standard car door hinges etc. Instead I found these. Pressed steel & nicely shaped -much more interesting than gate hinges. Including the pivots & R clips, a fiver each. Bargain. These are about 8 inches long, but they also do a longer version. I'll either drill & bolt them, or find someone handy with a TIG welder -Brock -to weld them direct to the face of the tail gate. 

TrailerTek
Warren Farm,
Micheldever Station,
Winchester,
Hants,
SO21 3AS
01962-774988


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 10:08:47 PM
I picked these letters up from a stall at a steam fair a couple of years ago -before I bought the Pop. I was just going to decorate the shed with them or something. They'll fit the tail gate perfectly though. Early Ford pick-ups had the FORD script embossed into their tail gates. I was tempted to label mine FIELD -my surname. The Field Motor Company. Would've looked quite good in the same style as the Ford ones. Trouble is, it'd mean nothing to anyone else, unless they knew my name. So I decided MANKY would be better as, with the website logo on the doors, it'd be self explanatory.
These letters are aluminium, about 3 1/2 inches tall & held with star clips on the back. I'll fit them, probably with a big dollop of glue too so the clips can't vibrate loose, then we'll spray them black along with the rest of the body. Just something to break up the blankness of the flat tail gate.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 10:10:45 PM
Like this.


Title: Re: Manky's Pop.
Post by: spanners on November 20, 2009, 10:18:11 PM
youve got me thinking  ,again,  the cortina shape p100 used to have ford emmbosed in the tailgate i once cut one out and tacked it on to a new tailgate when i ,rebodied, a p1oo a few years back.,, i saved another srap tailgate incase i ever wanted to do it again,,,,,,,,,,,,,,,,,,,,i wonder where it is now  must stil be here somewhere ,unless dad has weighed it in


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 20, 2009, 10:25:19 PM
My tail gate's quite small -only 10 1/2 inches tall by about 3 feet wide, so not sure a full sized "Ford" would fit. Plus it ain't Ford powered any more. Panther Shaun might well be interested though if you're selling it.


Title: Re: Manky's Pop.
Post by: spanners on November 20, 2009, 11:45:22 PM
i,ll see if its about when it stops rainin ,,,,,,,,,,,,thank god were on top of a hill


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 21, 2009, 08:51:10 PM
some nice stuff goin on there Andy :) maybe do the manky sign on back in copperex?


Title: Re: Manky's Pop.
Post by: poprodder on November 21, 2009, 09:23:25 PM
don't get the M upside down!!! :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 21, 2009, 10:19:43 PM
 :P
My day off today, but had a few jobs to do at home, so still didn't get to the workshop till mid afternoon. It was absolutely pouring down & just one of those days when you don't feel like doing much. So I tacked the big washers to the end of the pick-up top tubes. I'll probably add another bead of weld, then blend 'em in with the flap wheel on the grinder. Should look O.K
-yeah, I know, blurry pics. Sorry.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 21, 2009, 10:23:42 PM
They'll look like this when fitted.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 21, 2009, 10:36:17 PM
You might have noticed I've also cut & welded a couple of vertical lengths of flat steel strap into the tail gate.
I've drilled the two hinges to take M8 button head allen bolts. Next job is to drill the straps to match & weld a couple of captive nuts to each.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 21, 2009, 10:37:35 PM
They should look like this. They'll be painted black along with the rest of the tail gate.


Title: Re: Manky's Pop.
Post by: brock on November 22, 2009, 12:25:25 AM
  just to hijack this for a moment,

   "p.s  still haven't got a starter motor for it  (maybe brock??)"
 
  I had a look today for you, sort of surprise present, surprise is where I should have had at least two, I actually have none ! No idea where they went to after we switched to a mini high torque one. Sorry.

  carry on. Coming together really nicely by the way


Title: Re: Manky's Pop.
Post by: spanners on November 22, 2009, 12:56:36 AM
thanks for looking ,brock,  i may by another complete engine with one there,s one on the net with a frost crack just hoping it,ll be cheap


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 22, 2009, 09:28:31 AM
Praise indeed Mr Brock. Thank you.
So when you coming over to help us piece the stainless headers together then?  ;D


Title: Re: Manky's Pop.
Post by: Mr_G on November 22, 2009, 01:05:11 PM
I picked these letters up from a stall at a steam fair a couple of years ago -before I bought the Pop. I was just going to decorate the shed with them or something. They'll fit the tail gate perfectly though. Early Ford pick-ups had the FORD script embossed into their tail gates. I was tempted to label mine FIELD -my surname. The Field Motor Company. Would've looked quite good in the same style as the Ford ones. Trouble is, it'd mean nothing to anyone else, unless they knew my name. So I decided MANKY would be better as, with the website logo on the doors, it'd be self explanatory.
These letters are aluminium, about 3 1/2 inches tall & held with star clips on the back. I'll fit them, probably with a big dollop of glue too so the clips can't vibrate loose, then we'll spray them black along with the rest of the body. Just something to break up the blankness of the flat tail gate.

Personally I think you should spray them MMM Red but its your baybee. Loving how it's coming together matey! keep us posted. (No pun intended)


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 22, 2009, 08:49:47 PM
Post Office red?
Not a bad idea G. I want to keep the truck fairly subtle, (ha, ha, haa!!) Less is more & all that. Don't want too many bits & bobs all over it to distract from the overall look. Continuing on the red from the logos on the doors would be good though. I'm hoping Clive will airbrush those on for me in a faded, worn out style. So maybe just highlight a few corners of the letters in worn out red too. Thanks G.


Title: Re: Manky's Pop.
Post by: Mr_G on November 23, 2009, 09:31:29 PM
No probs, glad I could be of some use to someone, that has to be a first lol.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2009, 12:01:41 AM
Nipped back out to the trailer shop today & swapped the tailgate hinge pivots -they weren't a matched pair. One was pressed together & the other welded. Could've adapted them but easier to just swap them. While I was there though I picked up more shiney stuff.
Two sets of luggage hooks. I'll probably fit these down each side of the pick-up bed floor. Handy to strap stuff down to. Also bought an adjustable linkage to connect the handbrake lever to the cable. The Reliant lever we have has a very similar pulley arrangement, which we thought we'd have to extend. With luck, this'll save us some work.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2009, 12:04:30 AM
More fuzzy photos I'm afraid.
Tailgate hinges now fitted. They bolt to captive nuts welded into the gate. The pivots bolt through the back edge of the pick-up framework, via more welded in captive nuts.
Up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2009, 12:05:21 AM
Down.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2009, 12:06:54 AM
Neither up nor down. Not sure the masking tape strap will hold though.


Title: Re: Manky's Pop.
Post by: ByzMax on November 25, 2009, 12:12:43 AM
Looking rather Smart that!


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2009, 12:14:38 AM
Why thank you Mr Byz.  :)
Next job was to cut a length of sheet steel to skin the outside of the tailgate. Normal body panel thickness, (16 or 18 gauge). These are the 3 1/2 inch tall, number plate type aluminium letters I'm going to fit to the gate. I don't want to over-detail the truck with loads of bolt-on bits, but Loony suggested we get a raised or recessed bead rolled into the panel around the letters. Someone like Valley Gas Speed Shop in Newbury, Berks should be able to handle that for us. This is what the skin should look like.


Title: Re: Manky's Pop.
Post by: TwistedPatience on November 25, 2009, 12:21:51 AM
Nice ;D


Title: Re: Manky's Pop.
Post by: twolanes on November 25, 2009, 12:23:44 AM
looking good mate,its coming on leaps and bounds.


Title: Re: Manky's Pop.
Post by: spanners on November 25, 2009, 03:55:22 AM
Neither up nor down. Not sure the masking tape strap will hold though.



as bad as me not even on the road yet and she,s got a load on ;D ;D


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 25, 2009, 04:31:16 PM
lovin it Andy ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2009, 06:51:35 PM
Thank you chaps.
Had a lousy day at work today so rather than grafting in the workshop all afternoon, Loony & I took a drive over to Newbury in Berkshire. We called at Valley Gas with our sheet of steel, but they were shut! So we nipped round to the body shop round the corner. Max, the owner, specialises in hand formed aluminium car bodies & does some truly beautiful work. He's currently working on a Chevy engined model A type pick-up, completely built from scratch. 'Tis lovely.
"We're building a pick-up too" -we showed him our scrappy old bit of tin with the swage line drawn on in Tippex pen. I'm sure he was impressed.  :P  Said he'd have it done for us by Friday, so we'll nip back & collect it then. If he doesn't mind, I'll take the camera & grab some shots of his work for you.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 25, 2009, 06:58:32 PM
Some inspiration, emailed to me by Brock. Taken from Ger Peters' Dutch Courage Graffix site.
I don't think we've got it too far wrong.

http://www.dutchcouragegraffix.com/port_en.htm


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 27, 2009, 10:01:15 PM
Back to Max the metal magician's workshop this afternoon to collect the tailgate panel. Coo, that looks posh. Very nice. A raised bead, about half an inch wide. 20 quid.
The panel's slightly oversize at the moment so needs trimming down to fit the frame. The space either end of the centre piece will be filled by the hinges.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 27, 2009, 10:13:50 PM
Here's the pick-up Max is building. Everything hand-formed in aluminium. The customer stipulated a couple of things, like it had to be a 4 seater cab unit, but otherwise Max has been left to get on with it however he sees fit & the owner drops in every few months with a large cheque. He plans to use it as his daily driver. He's a builder & actually wants to carry building materials in the back. Next job is an aluminium removable hard top. Hopefully on the road next Spring. Gorgeous.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 27, 2009, 10:24:53 PM
Also in the workshop is this Austin 7 engined special. Someone else built it but Max created the boat tail & radiator surround. The owner wants to replace the little Austin motor with a Reliant!
Max doesn't even have a company name -he has enough work that he doesn't need to advertise, but if you need some quality ali' fab' work done, give him a bell.
07885-302234.


Title: Re: Manky's Pop.
Post by: BikerGran on November 28, 2009, 04:15:34 PM
My brother has an Austin 7 special with an ally body not too dissimilar from that, more rounded at the rear hence we always called 'the bomb' and it's painted brg.  Hasn't been on the road for years now but he won't part with it. 
I understand it's rather difficult to drive as the engine is a racing one - and I know the gear ratios are a bit odd so maybe that's a racing one too, I don't know much about them.
I've sometimes wondered if I could persuade him to part with it but given the difficulty of maintaining it I've never tried - but replacing the engine/box with Reliant lump seems like a good idea.  However I rather doubt whether I'd be able to climb in and out of it now!



BTW Andy I love the lettering on your tailgate but I think it would look better the same colour as the tailgate rather than red.  Just my opinion.


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 28, 2009, 11:31:19 PM
The little roadster's tiny -Max says he can't even get in it -very narrow seat, tall gearbox tunnel, big steering wheel & high mounted pedals mean there's very little space in there. Looks a lot of fun though.
My original intention was to leave the lettering black, same as the tailgate, but I quite like the idea of just touching in a few corners here & there with faded, scrubbed out red -just enough to make it readable from a car following me down the road!
Panel marked up & drilled & letters tapped into place & clipped with star washers, (forgot to take a piccie of the back).


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 28, 2009, 11:50:08 PM
I wasn't sure how much the panel would stretch or shrink when Max rolled the bead in it, so I cut it deliberately oversize. Loony & I centred the lettering over the tailgate framework today & marked the bolt holes for the hinges. Once they're drilled the panel can be trimmed to fit & welded to the frame.
Job done.
Just propped in place for the piccie here -I know it's not central! Everything, including the hinges, will  be painted black.


Title: Re: Manky's Pop.
Post by: poprodder on November 29, 2009, 08:24:05 AM
(http://i272.photobucket.com/albums/jj194/hery_jatmiko/thumbs_up_smiley-1.gif)


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on November 29, 2009, 05:03:02 PM
that looks brill did he press it to lift the bead out of the metal or use a tube  cut down etc ? i now im dull :) anyway looks really proffessional m8


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2009, 05:29:35 PM
The sheet's rolled between two wheels, one with a raised centre & the other with a matching recessed one to press the shape into the metal. Takes a lot of practice to produce perfect curves like this though. 

Here's one on Ebay for 175 quid.

Ebay roller (http://cgi.ebay.co.uk/Bead-Roller--Swaging-Machine--Bead-Forming-Machine_W0QQitemZ250524909248QQcmdZViewItem?rvr_id=&rvr_id=&cguid=7c27da5611f0a0aad354d024ff6c9430)


Title: Re: Manky's Pop.
Post by: BikerGran on November 29, 2009, 07:59:09 PM
I can see how that works but I'm surprised it doesn't deform the rest of the sheet.


Title: Re: Manky's Pop.
Post by: TwistedPatience on November 29, 2009, 08:53:10 PM
'Tis Magik that is! ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on November 29, 2009, 11:34:27 PM
The edge of the sheet's slightly wavey, but I cut it over size anyway so will trim back fine. I was concerned the centre of the beaded area would distort so didn't drill the letter mounting holes till it had been rolled, but it's fine.


Title: Re: Manky's Pop.
Post by: panthershaun on November 30, 2009, 08:50:13 AM
thats looking the bo******* mate  ;) ;) hoping to get up the barn today to work on mine if the chuffing rain stops long enough for me to fix the waterfall that is pouring into my garage first  >:( >:( >:(


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 01, 2009, 09:07:30 AM
Yeah, the shed at the end of our garden is the same Shaun. Must do something with it soon.
Here's the back of the tail gate showing the clips that hold the letters in place.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 01, 2009, 09:18:35 AM
Now since this is a warts n all build diary, I'll admit to a small cock up on my part- when we trimmed the panel to size & Loony tacked it in place, it became obvious that the top edge of the frame dips in the middle. I can't believe I put enough heat into it when I welded the corners together to bow the box section out of shape, but over it's metre length, it drops by 5mm in the centre. Bugger. A central brace would've prevented it, but I didn't think it was necessary. It probably wouldn't show once it's painted & fitted, but would really annoy me to know it's wrong.
So I think I'll cut a slice off one side of a piece of box section, leaving a couple of mill of the return edge on either side to keep it's shape & add it in on top of the frame to level it up. A minor problem. 


Title: Re: Manky's Pop.
Post by: poprodder on December 01, 2009, 05:26:52 PM
that looks real manky!!!   lol
excellent progress.


Title: Re: Manky's Pop.
Post by: morrag on December 01, 2009, 07:20:00 PM
There's shed builders, there's even talented shed builders, then there's guys like Max! its not the kit , its the man's talents and expertise, truly something special.......


Title: Re: Manky's Pop.
Post by: SteveRedd on December 02, 2009, 08:51:44 AM
you could always fabricate a nice capping piece Andy, perhaps in ally or stainless.....saves scratching the top of the tailgate too


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 02, 2009, 11:26:59 PM
We had another look at it today & decided when we skin the inside of the gate, we'll add a fold top & bottom of the sheet to square off the edges.
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 02, 2009, 11:37:47 PM
Lots of jobs to do around the back end of the Pop, so time we pushed on with them.
Another long, lousy day, trudging the streets delivering the mail in the rain today. Didn't get to the workshop till gone 4pm, by which time it was dark. I took a look at the Reliant fuel tank we're going to fit under the back of the chassis.
First I had to remove the original filler neck from the side as we're going to weld a new one in the top. Then I cut a disc of 2mm steel to blank the resulting hole. I also removed the original mounts & cut out a rust patch. Loony & PD have borrowed a TIG welder from a mate, so now they've got something to practice on!   


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 02, 2009, 11:44:25 PM
As the tank's going to be slung under the back of the chassis, it needs some straps to hang in. I didn't have any flat steel strap though, so went with a few off-cuts of the 1 inch square box section I used for the pick-up framework. After carefully cutting & clamping the pieces together at 90 degrees, ready for welding, Loony pointed out that the tank tapers, so my supports need to follow it. The first bits tacked together. These mounts will eventually bolt to the underside of the chassis.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 03, 2009, 11:23:26 PM
Mr Lunatic has fired up the TIG & welded in the filler hole blanking plate & started on the rust hole patch. He's only got a couple of hours of TIG experience but seems to have managed a fuel proof job. Well done mate. And I've welded up the tank straps. Next job is to cut them to length & weld flat tabs on the ends to bolt to the chassis.
Anyone fancy machining me some threaded mounts? 4 of 'em. Mild steel, 80mm long by 16mm diameter & bored & tapped to M8 -please.  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 03, 2009, 11:26:58 PM
Meanwhile Loony & PD are still plugging away at the Mudster roll cage. Should be finished this weekend.


Title: Re: Manky's Pop.
Post by: ByzMax on December 05, 2009, 03:14:16 PM
Andy it's not the corners that have distorted the tailgate it's the hinge mounts. As they have cooled post welding they have pulled the top rail down through shrinkage.


Looks cracking though! Nice bit of work!


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 05, 2009, 10:34:15 PM
Makes sense Byz. Fixable though.
Another long, long day at work today, so only a short workshop visit this evening. So I used it to tie the 2 straps together to form a cradle for the tank to sit in. We'd talked of welding them direct to the tank, but I think vibration might fracture the thin tank base, so I'll add a couple of locating tabs & line the cradle with rubber & bolt the tank into it.
Having checked it would all fit in the chassis, next job is to weld some flat mounting tabs to the framework to fix it to the underside of the chassis. Following suggestions elsewhere on the forum, I'll weld a nut into the end of a tube to form the chassis mounts.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 05, 2009, 10:38:37 PM
The Suzuki Vitara's almost done. Just some final welding of the tubes & shaping of the ends of the rock sliders to do, but as it's being done outside, rain's stopped play for the time being.


Title: Re: Manky's Pop.
Post by: SteveRedd on December 06, 2009, 11:30:15 AM
that looks like fun...I had one of them for 2 years and was amazed how well it went off road...on serious landy based events too


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 08, 2009, 09:51:21 PM
Still plugging away at the Pop, an hour or two every day after work before I go home if I can.
Today I welded the mouting tabs to the tank cradle & drilled them for the mouning bolts. The back ones will bolt up into the underside of the rear chassis cross member, while the front ones wrap around the chassis & bolt into the front face of it. This is because the cradle's slightly too wide for all 4 feet to mount to the underside of the chassis. Got to be that width for the tank to fit in it. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 08, 2009, 09:53:59 PM
My beautiful photogaphic assistant, Mr Lunatic, demonstrates how it fits.
Should all be hidden inside the pick-up side panels when they're done.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 08, 2009, 09:57:55 PM
The tank'll sit in the cradle like this. Enough room between the bed floor cross member & the tank for a strip of rubber. The tank will locate on a couple of tabs welded to the cradle. Eventually this'll all be hidden under the floor.


Title: Re: Manky's Pop.
Post by: peanut on December 08, 2009, 10:18:14 PM
Some phenomenally long hours being worked at the sorting office this week - just be careful operating all them sharp spinning and hot melty things at home when you're tired, Manky: Don't want you hurting yourself! As a mere Christmas Casual I appreciate the effort that's going in at the moment in Royal Mail, even if nobody in the outside world seems to. I've become something of a fan, but one that's despairing of an organisation that does so much right and yet doesn't let anybody know!


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 08, 2009, 11:11:16 PM
Coo, some positive praise at last!
Welcome to the wonderful world of the Post Office Mr P!


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 09, 2009, 07:24:59 PM
My day off today, but I had a phone call this morning from AfghanMan. He lives in French Franceland but is over here for a week or two & asked to come see us. Nice chap. Very nice to meet you Paul.
He brought us a pressie. Two door latches from genuine French house doors. I'd planned on using the plainer, chunkier looking one on the Pop, but we've decided to go with the more ornate one instead.
Turning the handle moves the rods in & out. Normally this would be fixed vertically to a door, but we're going to mount it horizontally with the bars exposed & locking into either side of the pick-up framework.
I was concerned it might look too fussy & girly for a pick-up truck but it's grown on me. It's quirky & different & has that all important little bit of history behind it. I like recycling stuff, rather than just buying something new. Loony suggested chrome plating it, (can you chrome cast iron?). Failing that, maybe that chrome effect powder-coat, or even just gloss black, the same as the rest of the bodywork?  Thanks Paul.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 09, 2009, 07:30:22 PM
The pick-up bed's never really going to be used for serious parts hauling, so a handle protruding into it won't matter. Having travelled over to the workshop, I used the time there to cut a couple of pieces of 3mm plate to mount the lock on. Then we nipped over to the local tool shop for some M4 countersunk stainless allen bolts to fix it with & some nuts to weld to the back of the plate.


Title: Re: Manky's Pop.
Post by: BikerGran on December 10, 2009, 02:37:31 PM
Were you thinking of chroming the whole thing or just the handle?  Will there be any chrome on the rest of the car, ie door handles?


Title: Re: Manky's Pop.
Post by: Firery Fred on December 10, 2009, 08:44:44 PM
Really nice touch that,Andy


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 10, 2009, 09:33:12 PM
I quite liked the flush fitting garage door lock Brock posted earlier, but think it's a bit modern for a 1950s truck. The whole mechanism would be surface mounted Bobbi, so could chrome the bars as well. Whadya think? I agree- if there's shiny stuff at the back it should be balanced by shiny stuff at the front. I don't want to go too blingy. The door handles are chromed & so are the door mounted mirrors. Maybe just pick up some of the suspension parts in chrome. The other option is to paint the tailgate handle black.   


Title: Re: Manky's Pop.
Post by: BikerGran on December 11, 2009, 02:27:04 AM
If it were me I would chrome the handle but not the rest of it - but that's just me.


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 16, 2009, 12:40:51 AM
The Christmas rush is really kicking in at work now, (I'm a Postie -stop buying stuff online you lot! I'm the poor sod that has to lug it all round the streets!). By the time I finish work, get changed & drive to Loony's workshop, he's already heading home. So much to do yet, so I need all the garage time I can get.
I've been thinking about that tailgate handle. Love the idea of re-using something that's had a previous life somewhere else, but thought it was just a bit too girly & fussy & did actually look like a domestic door handle. Too Laura Ashley as Loony put it.
So I'm swapping it for the other handle AfghanMan supplied. Much simpler, more in keeping with a truck. Loony's got a bit of a thing for holes though, so I attacked it with the drill to add some detailing, then buffed off the thick layer of paint with a Scotchbrite wheel on the angle grinder.


Title: Re: Manky's Pop.
Post by: afghanman on December 16, 2009, 12:42:04 PM
looks good Andy 8)do you want the matching end bits Iv'e got or are going to make something?


Title: Re: Manky's Pop.
Post by: Simple Simon on December 16, 2009, 05:10:59 PM
 8) 8) 8) 8)


Title: Re: Manky's Pop.
Post by: BikerGran on December 16, 2009, 06:59:56 PM
Yes that one's definitely more the thing!


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 16, 2009, 11:28:38 PM
Another day lost today as Loony had to go help a mate fix their car.
Yes please Paul, the end caps would be much appreciated. I'll PM you my address. Let me know the postal cost & I'll Paypal it to you or send a cheque.
Very nice to meet you the other day by the way.  ;)


Title: Re: Manky's Pop.
Post by: Firery Fred on December 17, 2009, 07:40:33 PM
 8)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2009, 11:05:01 PM
Yet another day of trudging the streets delivering Christmas cards 5 days too late.
I've been carrying that damn tailgate handle around in the boots of various cars for a fortnight now. Just had time to call in at Loony ltd this evening before Mr L locked up for the day. We tack-welded the mounting plate to the tailgate & bolted t'handle to it. Taa daa! So glad to offload the thing out of my car at last!


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 30, 2009, 11:22:46 PM
Then a little flash of inspiration from young Loony. The off cut ends of the semi circular tailgate rods are a perfect match for the embossed swage line on the cab doors. We'll carefully bend them to the curve of the cab back & chop up the spare lock assembly if needed to continue the swage line across the cab under the rear window. That'll help to make the Ford Pop front bodywork & Morris Minor back blend together convincingly. Sort of double recycling.


Title: Re: Manky's Pop.
Post by: gazzagood on December 31, 2009, 10:55:21 AM
nice job Mr manky i like it. good how you double recycling.even i ain't that good.well spotted Mr loony. ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 31, 2009, 03:20:28 PM
Hopefully not tempting fate by saying it, but a lot of this build seems to have just fallen into place. It's taken a lot of work, even just getting this far, but considering we haven't really planned it out that much, most of it's worked out pretty well -so far.


Title: Re: Manky's Pop.
Post by: afghanman on December 31, 2009, 05:27:40 PM
That was a bit of luck Andy 8)


Title: Re: Manky's Pop.
Post by: Manky Monkey on December 31, 2009, 10:20:29 PM
Hi Paul. Really appreciate your lock assembly donation. We're making good use of all of it.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 04, 2010, 05:17:38 PM
Paul tells me the end caps for the tailgate lock are in the post from Franceland, so thanks in advance for those Sir.
Not much going on on the Pop build over Christmas & New Year, but Taz & I were in the local saddlery suppliers yesterday & I picked up this pair of black leather straps for a bargain 7 quid. About 4 & a half feet long by an inch wide. Planning to strap the old Pop fuel tank down to it's mounting stand in the bed of the truck with them. It'll be bolted in place from underneath so the straps are just for show. The tank won't be fitted until after the SVA test anyway.
I've come to a bit of a deal with Loony. He's going to have my Triumph Speed Triple bike in return for some cash & services rendered on the Pop. I've hardly ridden it all year & he wants it, but can't raise the full value in cash. Sorted. So he should be putting in some after-work hours on the Pop bodywork. This is kinda a joint build between us, so I'm happy to trust his judgement & let him carry on in my absence.


Title: Re: Manky's Pop.
Post by: BikerGran on January 05, 2010, 09:12:18 PM
Barter!  That's excellent!


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 05, 2010, 09:31:13 PM
He's one of the Simpsons isn't he?
Don't think I'll be delivering the bike just yet though.


Title: Re: Manky's Pop.
Post by: poprodder on January 06, 2010, 11:43:53 PM
wots that white stuff?

none here in norfolk!!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 09, 2010, 09:03:24 PM
Received the tailgate lock end-caps in the post from AfghanMan today. All the way from France. Shame I can't get to Loony's workshop to fit them because of the snow!
Thanks Paul.
They were out of focus when I took them out of the envelope -honest.  :P


Title: Re: Manky's Pop.
Post by: afghanman on January 10, 2010, 08:26:16 AM
glad they arrived okay, they might have got lost in the snow!


Title: Re: Manky's Pop.
Post by: SteveRedd on January 10, 2010, 11:02:23 AM
Here Andy, I just realised there's 118 pages and you still ain't done  ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 10, 2010, 01:50:43 PM
It's turned into a bit of an epic hasn't it. Hopefully with a happy ending -eventually.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on January 10, 2010, 07:01:36 PM
It's turned into a bit of an epic hasn't it. Hopefully with a happy ending -eventually.
ooo you changed yer avatar ;D chucked me for a min lol


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 10, 2010, 07:40:31 PM
 ;D Fancied a change.


Title: Re: Manky's Pop.
Post by: Simple Simon on January 10, 2010, 07:43:47 PM
;D Fancied a change.

Dont let Taz hear you say that :D


Title: Re: Manky's Pop.
Post by: BikerGran on January 11, 2010, 09:30:24 PM
It's turned into a bit of an epic hasn't it. Hopefully with a happy ending -eventually.

But it's turned into an epic cos you've done lots of stuff to post about! - it used to be just you saying one day...  maybe....  should I....  could I........


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 11, 2010, 11:41:54 PM
I always used to read the write-ups in magazines & wish they'd go into more detail about the builds. So when I started my various projects I set out to show as much info as I possibly could. Not that I'm an expert at all, but if it helps or inspires one person then I've done my job.  ;D


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on January 12, 2010, 12:04:47 PM
I always used to read the write-ups in magazines & wish they'd go into more detail about the builds. So when I started my various projects I set out to show as much info as I possibly could. Not that I'm an expert at all, but if it helps or inspires one person then I've done my job.  ;D
wouldnt want to see your builds any other way m8 ;D


Title: Re: Manky's Pop.
Post by: Clive on January 12, 2010, 04:58:55 PM
I always used to read the write-ups in magazines & wish they'd go into more detail about the builds. So when I started my various projects I set out to show as much info as I possibly could. Not that I'm an expert at all, but if it helps or inspires one person then I've done my job.  ;D

You've done your job then buddy!!!! ;D

I'm inspired all the time, when I come on here and see the work you, and others, push out!! In fact, I'm that inspired I start a welding course (at Night School) on Monday!!!!  :o

Clive


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 12, 2010, 05:29:33 PM
Well done mate. I'd been messing about with welders for years, but never 100% certain I was doing it right. Flap & I enrolled on a welding course at our local tech college when we built his trike. A couple of hours, one evening a week. Well worth the money. Taught me a few things I didn't know, but more importantly, gave me the confidence to know I'd been doing it more or less right.
Knowledge is always a good investment. It'll last you a lifetime.


Title: Re: Manky's Pop.
Post by: Clive on January 12, 2010, 06:03:48 PM
That's exactly what this is! Two hours, one night a week, for ten weeks!!!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 12, 2010, 07:21:43 PM
Sounds like the same course then. We did a little bit of gas welding, then went on to MIG. We were allowed to take in our own MIG units -funny to see everyone comparing welders, like boy racers comparing their cars. Our instructor happened to be a Postie during the day -so he spent the whole course taking the mickey out of Flap & me. If you're building something, the instructors usually don't mind you taking it along -more interesting for them than just welding scrap bits of steel together & you can learn on something you're actually going to keep.
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 14, 2010, 11:21:52 PM
Finally got to spend a little time on the Pop again today after a couple of weeks off due to heavy snow, car problems etc, etc. Hoped to get loads done, just to make it look like we're making progress. Yeah right.
AfghanMan very kindly mailed me the end caps for the tailgate handle he brought me all the way from France recently. Should be a 5 minute job to fit them then.
4 hours later...
I marked & drilled the tailgate frame & tapped the holes to M5, Bolted the caps on -& couldn't turn the handle. It was locked solid. Loosen the cap bolts & it turns fine. Checked the locking bars were running true, filed out the slots in the caps that the bars run through, even cut off the plate the handle bolts too & re-fitted it, twice. No joy.
Took me hours to finally twig that there's a 2mm gap behind the bars where they exit the handle casting. I needed to cut some 2mm shims to go between the end caps & the tailgate frame. Easy to fix once I realised the problem, but that was an entire afternoon wasted. Next I need to make some brackets for the bars to lock into.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 14, 2010, 11:28:18 PM
I'm very grateful to AfghanMan for the lock, but I'm guessing the handle & caps came from 2 different assemblies. Like I said, easy to fix, once I found the problem.
Not much building time. Lots of thinking time. I think slow.  :P


Title: Re: Manky's Pop.
Post by: gazzagood on January 15, 2010, 10:48:54 AM
coming on know Andy at this rate you'll get it finished before the trike. ;D ;D oh got me temp gauge today thanks for the message. 41 quid know inc 3 pound postage. but looks great.thanks  :-*

 gaz


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 15, 2010, 11:03:52 AM
That'll be a "Moon" water temperature gauge, same as the one fitted on my trike engine. Gone up a bit in price since I last looked then. Did you fit yours to the thermostat housing like mine, or remotely somewhere?
I've got another week's holiday in February, so hoping to make up for lost trike building time then. Maybe.


Title: Re: Manky's Pop.
Post by: gazzagood on January 15, 2010, 11:10:56 AM
yes I'm going to fit it to the thermostat housing like yours can't remember know where you got your adaptor from did you say a plumbers merchants.

gaz


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 15, 2010, 11:20:03 AM
Had it machined in stainless by SaddleBags, but haven't seen him for a while.
You could probably find something suitable at a plumbers merchants though. If I remember right, the 'stat housing mounting hole is bigger than the gauge fitting, so you just need a plug that'll screw into the stat housing, with a threaded hole in the middle to take the gauge. If you get stuck, try Twisted Patience, or any of the other lathe owners, here. Wouldn't be a big job to knock something up if you can figure out the thread sizes.


Title: Re: Manky's Pop.
Post by: gazzagood on January 15, 2010, 11:25:15 AM
 :-*   ;D


Title: Re: Manky's Pop.
Post by: Mr_G on January 15, 2010, 10:07:05 PM
Sweeeeeet.


Title: Re: Manky's Pop.
Post by: afghanman on January 16, 2010, 08:47:35 AM
Probably when the bars ere longer and mounted on a wooden window frame it would not have been a problem.
too late now but you could have just kinked the bars a tad! :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 16, 2010, 09:32:33 AM
Just what I thought Paul. My Pop's not exactly precision engineered & I like the way everything's fettled by hand to fit. Gives it a bit of character!  ;D


Title: Re: Manky's Pop.
Post by: panthershaun on January 18, 2010, 02:52:57 PM
I actually looked at mine yesterday  ;D ;D ;D


Title: Re: Manky's Pop.
Post by: afghanman on January 18, 2010, 04:39:31 PM
Did it look back? its probably sulking through neglect ;D


Title: Re: Manky's Pop.
Post by: madron on January 18, 2010, 04:42:17 PM

I actually looked at mine yesterday 


lookins no good get yer hands dirty


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 18, 2010, 06:08:26 PM
You've not mentioned your Pop lately Shauny -which means you're either miles ahead of us, or miles behind.  ;D
About time we had an update ain't it?


Title: Re: Manky's Pop.
Post by: afghanman on January 18, 2010, 06:41:31 PM
Iv'e seen it ,,,,,,,,,,,,,,,,,,,,,Your ahead ;)


Title: Re: Manky's Pop.
Post by: panthershaun on January 19, 2010, 02:33:19 PM
well ahead  :'( :'(


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 19, 2010, 10:26:12 PM
The cr*p weather & various other factors mean I haven't achieved anything on mine for a couple of weeks now. Fully intended to spend a couple of hours on it after work today -then my Royal Mail van broke down half way round my delivery this morning. The Post Office have rented a fleet of small vans while they re-shuffle the delivery system & the RAC deal with any breakdowns. So I had to wait for them to arrive, then wait for my depot to send out a replacement van, then carry on delivering. Didn't get finished till 4pm after leaving home at 5 in the morning & definitely wasn't in workshopping mood. 


Title: Re: Manky's Pop.
Post by: panthershaun on January 20, 2010, 12:55:47 PM
yesterday I started work at 04-30 and finished 18-30, bloody knackered today  :-\


Title: Re: Manky's Pop.
Post by: SteveRedd on January 20, 2010, 02:07:01 PM
How many more times Shaun....sitting on yer arse in front of the telly ain't work !!


Title: Re: Manky's Pop.
Post by: panthershaun on January 20, 2010, 03:21:39 PM
 :P :P :P :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:00:59 AM
Here's mine so far Shaun. How's it compare to yours?
Loony was having a bit of a vehicle re-shuffle at the workshop today. Although it was Sunday, Taz was working, so I nipped over from Guildford for a couple of hours. Did a little bit of work on the tailgate inner skin, but took the opportunity to drag the Pop out of the shadows & into the daylight for a proper look at how things are going.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:03:21 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:04:30 AM
Hmm.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:07:08 AM
After working on it up close in the shop for so long, it was good to be able to stand back & view it from a distance. The swage line on the doors doesn't line up with the top of the pick-up bed. The body sits level to the ground, but the bed is slightly raked because of the taller rear tyres.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:10:12 AM
Not a big problem, but precisely why it pays to wheel your projects out of the workshop & take a good look at them from a new perspective if you can. The body's just tacked to the chassis at the moment, so it was easily fixed by grinding off the rear tacks & lifting the back end up by an inch.
That's better.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:11:46 AM
One of the VW camper van repair panels we're using to create the bed sides, clamped in place.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:13:47 AM
The rear bottom corners of the cab are Leyland Mini front wings stood on end & the roof panel's cut from the back of a Rover P6 roof. Body's from a 1950s Ford Pop saloon & the cab back's from a 1970s Morris Minor pick-up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:16:54 AM
We've pushed the front axle a few inches further forward than normal, which gives us more room to shoe horn the Rover motor in. We'll stretch the bonnet top & sides to suit. The stainless exhaust headers will come out over the chassis rails & sweep backwards, filling the gap between front wheels & cab.
Although it sits quite low, there's still plenty of ground clearance.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:18:02 AM
Tailgate propped in place.
Indicators will fit in the ends of the pick-up top tubes. Rear lights & number plate will be in the panel under the back of the chassis.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:20:27 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:21:47 AM
PD & Loony have almost finished that Suzuki Vitara roll cage.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:22:14 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:22:58 AM
Loony's arty shots.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:23:20 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 01:23:46 AM
Mine.


Title: Re: Manky's Pop.
Post by: SUMO on January 25, 2010, 11:06:16 AM
thats looking proper that is


Title: Re: Manky's Pop.
Post by: panthershaun on January 25, 2010, 11:29:24 AM
looking good mate, nice lines and a cool stance.
I'm still working my way slowly through the cab, I want to get that all nice and solid before I start on the pickup bed etc. I will try and get some pic's later as I'm going up there to do some work on my PAV trailer.


Title: Re: Manky's Pop.
Post by: afghanman on January 25, 2010, 12:23:56 PM
Give you a taster of whats in this months mag Shaun 8)
(http://i171.photobucket.com/albums/u284/afghanman_photos/01-25-2010124315PM.jpg)
(http://i171.photobucket.com/albums/u284/afghanman_photos/01-25-2010124544PM.jpg)


Title: Re: Manky's Pop.
Post by: blair on January 25, 2010, 04:25:21 PM
not sure if that mag artical is French but for some reason MM i thought your pop looks French , dont know why its not like ive seen heaps of french modded vehicles.

 ??? ??? ??? ??? ??? ??? ??? ??? ??? ???


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 25, 2010, 05:34:06 PM
It'll have a French door handle on the tailgate -that's about as Frenchified as it gets. Maybe it's the truck being sat in a rural setting that gives that impression? -just outside rural Basingstoke!
I know mine's not that unusual -there's lots of very similar trucks in the mags, but it's the only one I've ever built & my first "proper" hotrod build, so I can't wait to fire it up & blat off up the lane in it.
Lots of jobs are sort of half done at the moment. Everything needs properly finishing off so we can move on to the next bits. Getting there though.


Title: Re: Manky's Pop.
Post by: Mr_G on January 25, 2010, 09:52:31 PM
Coming on nicely I see. Nice to see it in some different surroundings, instead of the garage.

G.


Title: Re: Manky's Pop.
Post by: poprodder on January 26, 2010, 12:05:26 AM
thats looking the bo****ks, looks better with the bed sides in. ;D


Title: Re: Manky's Pop.
Post by: blair on January 26, 2010, 09:01:22 AM
oh dont get me wrong MM im not slating your work at all, its comming along very well and i like that you are using pannels from other vehicles and handles from other countries, i dont read hot rod mags so to me yours is unique   


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 26, 2010, 10:03:34 PM
Nah I took it as a compliment!  ;)
Spent a couple of hours at the workshop this afternoon, but it was absolutely freezing there. I don't work well at low temperatures! Can't think straight when I'm shivering with cold.
So Loony tacked the inner skin on the tailgate & started filling the gap between the flat top of the new skin & the frame, which I'd bowed out of shape with too much heat. This thing now weighs a ton!


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 28, 2010, 10:19:18 AM
I nipped down to B & Q for some 30 x 4mm flat strap & hacksawed & hammered it into 8 curved mounts to bolt up under the mudguards. I've already bent some 20mm O.D ERW tube for the struts so now just have to marry the flat strap to the round tube. I don't want the flat bits to show when they're fitted, but need the clearance between the tyres & guards so don't want the round tube running underneath. So the tube needs to end at the edge of the guard & be continued in flat strap -if that makes sense.


Title: Re: Manky's Pop.
Post by: blair on January 28, 2010, 01:00:16 PM
you could cut a slot into the top of the tube for the bar to slide into , you could then weld the tube internally to give a clean interface between tube and bar ?
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 28, 2010, 09:07:16 PM
Yeah, I think it'll be something along those lines. Don't really want to cut into the edge of the guard if I can avoid it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on January 29, 2010, 10:11:42 PM
Sort of like this.


Title: Re: Manky's Pop.
Post by: twolanes on January 29, 2010, 10:34:54 PM
Sure is coming on a treat. looking foreward to seeing it at Basingstoke mate.


Title: Re: Manky's Pop.
Post by: blair on February 01, 2010, 10:28:33 AM
Sort of like this.

yep exactley like that  ;D


Title: Re: Manky's Pop.
Post by: afghanman on February 01, 2010, 11:19:24 AM
Nice guards Andy what radius are they and where did you get them?,,,,,,,,,,Thinking Bike here!


Title: Re: Manky's Pop.
Post by: poprodder on February 01, 2010, 08:00:05 PM
i'll have a set andy!!! ;)           ;D      lol

good work.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 01, 2010, 10:21:10 PM
 ;D If only I were that talented! Not my handiwork I'm afraid.
They're the work of Mr Darren Goodgame from Oxford. He had a stand at one of the Beaulieu autojumbles, showing a complete aluminium bodied roadster he'd built.
He works from a small industrial unit in Cowley, Oxford.
Brooklands Bodycraft.
brooklandsbodycraft@ntlworld.com
01865-451914.

I gave him the measurements by email, (16 inch wheels on the back & 15 inch on the front), but once he'd produced the basic shape we drove up & took him a couple of wheels & tyres to try them on. He'd assumed I wanted them mirror polished & quoted me 50 quid per guard -might sound a lot, but not bad for custom made, one-off products. There's a good few hours in each one. I've seen repro steel vintage bike ones at bike jumbles for 80 or 90 quid each.
When I told him I planned to paint them, he knocked a fiver off the price of each one, so they cost me 45 quid each. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 01, 2010, 11:17:01 PM
Spent a couple of hours this afternoon messing about with the guard. I had to notch the sides a little then drilled it & fitted the struts with a bunch of stainless M8 button headed bolts.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 01, 2010, 11:24:07 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 01, 2010, 11:32:40 PM
Got to bolt it to the axle now. I've cut a fan shaped 3mm plate & will knock up a clamp to weld to it & bolt to the axle.


Title: Re: Manky's Pop.
Post by: spanners on February 01, 2010, 11:35:42 PM
lookin pretty good ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 01, 2010, 11:36:50 PM
Fank U.
They'll be painted gloss or satin black. Just sat on the tyre here, but will stand an inch or two off it when they're finished.


Title: Re: Manky's Pop.
Post by: blair on February 02, 2010, 12:24:22 PM
sweet as


Title: Re: Manky's Pop.
Post by: madron on February 02, 2010, 09:11:00 PM
mudguard mounts look very neat  and satin black would help em blend in comin on a treat now


Title: Re: Manky's Pop.
Post by: Clive on February 02, 2010, 09:37:11 PM
Have to agree! Starting to notice real progress on this now MM buddy!!! Keep it up! ;D

Clive


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 02, 2010, 10:07:37 PM
Appreciated guys.  ;)
Sometimes you feel like you're getting absolutely nowhere. I try & put in a couple of hours every day if I can, but that often means just cutting & filing one bracket or even just some thinking time.
I welded the gusset in this afternoon, allowing plenty of time between welds to minimise heat distortion cos I don't want the ali guard under tension or it might crack.
A very fuzzy photo, but you should be able to see that I need to drill a large hole in the gusset plate to allow access to the brake fittings.


Title: Re: Manky's Pop.
Post by: TwistedPatience on February 03, 2010, 07:52:22 AM
Kool ;D


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on February 03, 2010, 05:53:46 PM
looking beautiful Andy ;D keep at it m8 :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 06, 2010, 07:48:48 PM
See that little axle clamp -all afternoon it took me to make that.
Yeah, I know, I'm a slow worker. I prefer to think of it as careful & methodical.  :P
Not having any tube the diameter of the Sherpa axle, I had to beat a length of flat 30 x 4mm strap into shape over a former in the vice, then weld mounting tabs to it. There's a pair of corresponding tabs bolted to it at the moment. They'll be welded to the axle, so the clamp sits over the axle tube & bolts to the tabs.
I was tempted to just weld the mudguard struts directly to the axle tube, but this way, we have the option of removing them if we ever need to -should I change the wheels for example, or if we took it drag racing. Next time I'm at the workshop I'll weld the clamp to the struts & the tabs to the axle -then I've got to reproduce it all on the other side of the car.


Title: Re: Manky's Pop.
Post by: poprodder on February 07, 2010, 11:47:48 AM
good work andy, but is that enough support/strength to hold them mudgaurds up?
(or is there more to follow!!!)

chris.


Title: Re: Manky's Pop.
Post by: cunningplan on February 07, 2010, 12:37:22 PM
I thought that  ???


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 07, 2010, 11:44:18 PM
Hi guys. My trike guards are of 3mm aluminium, about 250mm wide, on larger sized tubes. They mount in a similar way, except the tube struts weld directly to the clamp, rather than via a vertical piece of flat plate. The Pop guards are much lighter aluminium, on smaller, lighter struts & are a third the width. So much less leverage.
However, I'll weld the first one in place, then yank it around a bit. If it looks like it's going to be a problem, I'll reinforce it all further. Appreciate the interest chaps.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 10, 2010, 09:59:58 AM
Tacked the struts to the clamp of the first guard yesterday. Loony's borrowed a TIG welder to play with so is going to practice on this with it. I've moved the struts to the outside edge of the clamp & added a small triangular gusset to the back, which should help stop the struts from drooping over the tyre. If that's not enough, I'll have to add a brace, running back to a point further inboard on the axle, but I really don't think the guards are heavy enough to be a problem.


Title: Re: Manky's Pop.
Post by: cunningplan on February 10, 2010, 05:42:22 PM
thats better  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 10, 2010, 06:41:44 PM
It's only a tiny gusset, but hopefully big enough to do the job. Can't make it any taller cos I need to bore a large whole through the centre of the fan shaped plate for the brake hose & bleed nipple.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 12, 2010, 11:17:40 PM
Second set of rear mudguard struts made, mudguard drilled & gusset tacked in place.   


Title: Re: Manky's Pop.
Post by: gazzagood on February 13, 2010, 12:37:36 AM
very nicely designed and made sir.your talent wasted as postie should of been sheet metal worker.or engineer.  ;D well done.mate


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 13, 2010, 06:59:50 AM
My Dad used to tell me, As a mechanic, you'd make a good dustman.


Title: Re: Manky's Pop.
Post by: BikerGran on February 13, 2010, 01:40:39 PM
Reminds me of the friend who once welded my exhaust for me - he was trained to use welding equipment when he was in the Marines and the instructor told them they were not to think they were welders, they'd just learnt enough to use the equipment without blowing up themselves or anyone else.

When it was done he told me it was guaranteed for 5 miles or 5 minutes down the road, wheichever came sooner!


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 13, 2010, 11:03:15 PM
 ;D


Title: Re: Manky's Pop.
Post by: texon on February 14, 2010, 02:25:58 PM
comin on a treat m8  ;) I agree with all the above COOL AS PANGUIN PISS  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 14, 2010, 02:39:55 PM
Hiya mate. Nice to see you back again. S-o-o much left to do, but getting there, slowly.


Title: Re: Manky's Pop.
Post by: blair on February 15, 2010, 08:31:49 AM
When it was done he told me it was guaranteed for 5 miles or 5 minutes down the road, wheichever came sooner!

i always give a sight Guarentee , once you cant see me that it guarentee finished


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 15, 2010, 02:02:00 PM
 ;D
Second rear mudguard welded up, ready for Loony to TIG weld the little triangular gusset in place, (marginally tidier than my MIG welding & in a confined space where it's awkward to get the MIG torch in. Off to Loony's workshop now to see if they look alright.
Spent ages measuring the height of the guard off the workbench in my shed & trying to hold everything square while I tacked it in place. Still not convinced the guard sits perfectly right compared to the clamp, but a small tweak on the clamp when we weld the tabs to the axle should bring it into line.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 15, 2010, 11:13:33 PM
Both rear mudguards tacked in place. I unbolted the pick-up bed from the chassis to check the alignment of the axle. We only roughly set it up when we fitted it. With some tweaking of the adjustable 4 bar linkages, it's spot on now. We're told the diff should be inclined upwards by 4 degrees, to allow for suspension travel. It is. I've added 1 inch thick stainless spacers to the bottom shock mounts, to ensure they move freely, without fouling on the axle.
The guards are hand-made & not entirely symetrical, but sit as equally as we can get them.


Title: Re: Manky's Pop.
Post by: BikerGran on February 16, 2010, 04:57:01 PM
That won't be noticed anyway when you have the body on as it's only on very rare occasions they'll be looked at from directly behind.

Lookin good!


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 16, 2010, 10:48:30 PM
True Bobbi. The bead down the centre of the guards lines up with the centre tread of the tyres, which is the most obvious reference point. The great Ed Roth, 60s custom car builder extraordinaire, used to say you can't look at both sides of the car at the same time, so they don't need to be identical, just close enough that people think they are.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 17, 2010, 08:31:51 PM
Bought a bag of holes & bolted some to each mudguard strut. The big ones are for access to the brake fittings on the back of the hub. Little ones are fake, just for show.  :)
Started drilling them as Loony was shutting up the workshop for the night last night & in my haste, drilled one in the wrong place. So had to weld it up again today & redrill it. Sorted. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 19, 2010, 10:50:56 PM
Mr Loony was busy paint spraying today, so not advisable to go waving welding torches about in the same workshop. So I collected the seats from the upholsterer instead. I bought these seat frames a couple of years ago from the Brooklands autojumble. They're reproduction Austin 7 Chummy seats, normally covered in brown leather.
50s hotrodders often used war surplus American bomber seats, pressed or folded in lightweight aluminium. These are a reasonable substitute & British -for my Britrod.
I was going to powder-coat them metallic silver to simulate aluminium, but will go with gloss black instead. In the spirit of recycling, I had the seat bases made & covered in black leather from an old Volvo seat, donated by Loony. Mike the upholsterer had to find 2 matching areas of unblemished leather, which dictated the eventual pattern. He had to mix & match the buttons to get enough good condition ones too, then create the red piping to add a liitle detailing. The bases have to lift out to give access to the brake master cylinder under the driver's seat, so Mike stitched a lifting tab in either side.
Verdict- suprisingly comfy.


Title: Re: Manky's Pop.
Post by: triker_Chewie on February 20, 2010, 01:13:36 PM
snazzy


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 20, 2010, 05:55:06 PM
 8) Sat at roughly the right height off the chassis on a couple of bits of wood. The passenger seat will be fixed, but we've got a seat runner from an old Peuguot hatchback so the driver's seat will be adjustable front to back & up & down. I was worried the seat foam would compress until your legs hit the metal seat frame, but when you're sat in the cab, your knees are bent enough that you're nowhere near the frame.
The backs of the seats are quite flexible & springy -we might have to add some strengthening struts to make them more rigid. Steering wheel & gearchange seem to fall quite comfortably to hand.
The commercial vehicle SVA registration test we're aiming for doesn't test anything inside the cab, so we could get away without seatbelts, but they're required for the MOT. If we'd used a bench seat we could've just fitted old fashioned lap straps, but individual seats require 3 or 4 point mounted belts. I'm thinking maybe 3 or 4 point racing harnesses. Some companies make them with a Y shaped top strap on an inertia reel, so when you undo them, they retract like a normal seatbelt. We'll make up a tubular semi rollcage around the back of the cab to fix them to.


Title: Re: Manky's Pop.
Post by: panthershaun on February 21, 2010, 02:27:41 PM
cool seats dude, looking forward to Thursday  ;) ;)


Title: Re: Manky's Pop.
Post by: poprodder on February 21, 2010, 09:02:21 PM
seats look good, but i'd need more comfort!!!


Title: Re: Manky's Pop.
Post by: twolanes on February 21, 2010, 09:18:57 PM
looking good inside there mate.


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on February 24, 2010, 08:28:04 PM
looks great, bout ready to drive Andy ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 24, 2010, 09:24:14 PM
Hmm, maybe just a little more to do before I can fire it up Gareth!


Title: Re: Manky's Pop.
Post by: SteveRedd on February 25, 2010, 08:31:37 AM
those seats were a good deal Andy, it's all coming together nicely


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 25, 2010, 08:01:17 PM
Thank you.  :)
Had a brief visit to the workshop from Mr PantherShaun this afternoon. Nice to see you Sir & to have someone new to bounce ideas off & compare notes with.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 26, 2010, 10:08:50 PM
Tailgate is now complete, apart from some tidying up around the top & bottom edge, where I bowed it out of shape by putting too much heat into the framework with the welder. The smooth inner skin is on. I had a 90 degree fold put in the top of the skin to level up the slightly curved frame. Just needs Loony to finish running the MIG around it all then a light skim of filler on the edges to smooth it out & it's done.
The locking mechanism donated by AfghanMan is also done. I cut a couple of bits of the box section I used for the framework, sliced them in two & slimmed them down before rewelding, then welding to the bed framework, to create two snug fitting slots for the locking bar to locate into.
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 26, 2010, 10:18:35 PM
I've been thinking about a means of holding the tailgate in the horizontal, open position. Not keen on lengths of chain, clanking about. Chain covered in plastic sleeve just looks tacky in my opinion. Maybe chain in a tight fitting leather sleeve. I've seen production pick-up trucks with hinged bars or rods to hold the gate open. In the end I've decided not to fit anything. I don't plan on carrying anything big enough to require driving with the gate open, plus as soon as I park it up with the tailgate open, people are going to sit on it, so it would have to be strong enough to support 2 adults. The handle would also get in the way. So it'll open for loading stuff but just drop right down. To be honest, it'll probably never need to open.
I've tacked in a couple of diagonal struts to stop the ends of the bed sides from spreading outwards as they're not tied into anything else. Trying to make the bed tough enough to withstand a couple of clumsy people clambering about in the back when it's parked up at meets.


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 26, 2010, 10:24:43 PM
You can see here where we modified the bed floor crossmembers to give extra clearance for the suspension travel. With the rear shocks on their softest setting & Loony leaping up & down on the back end as hard as he could, we could just get the upper 4 bar rods to kiss the underside of the bed frame. Cutting out a section of cross member gives more room for the rods to move & winding the adjustable gas shocks up a bit gives a firmer ride. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on February 26, 2010, 10:30:12 PM
Late this afternoon we lifted the pick-up framework off the chassis again & I MIG welded up all the tacked together box section. Once some of the welds have been sanded back flush, Loony can make a start on skinning the outside.


Title: Re: Manky's Pop.
Post by: BikerGran on February 28, 2010, 09:54:57 PM
Making progress all the time now Andy!


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 01, 2010, 12:02:21 AM
Praise indeed Bobbi  ;)
I'm spending a couple of hours a day at Loony's workshop. Trouble is, after getting up at 4.30 each morning & 3.30 on Saturdays, then putting in an 8 hour shift at the Post Office, by the time I've got changed & driven to Loony's place, I'm so knackered it's real hard to work up the enthusiasm to work on it. Gotta keep plugging away at it though or it'll never get done. I want to finish my trike too, but it's 7 or 8 in the evening before I get home & I definitely haven't got the energy to start a third shift in the shed.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 02, 2010, 10:52:51 PM
As I'm working on the pick-up bed, I may as well finish the back end before moving forward.
I've used a sanding disc on the angle grinder to smooth the welds on the framework where the body panels will fit. No point wasting time cleaning back ones that will be hidden behind the panels. Loony's working on a Bedford truck at the moment, but the framework's now ready for him to skin inside & out.
To qualify as a commercial vehicle, the internal length of the pick-up bed needs to be longer than the internal length of the cab. Ours is, just, but if we put the Pop fuel tank in the bed, the useable load space is measured from the back of the tank to the tailgate, which would be too short.
Our original plan was to fit a Reliant fuel tank under the bed of the Pop for the SVA test, then add the original cylindrical Ford Pop tank, sat in the bed, tucked up behind the cab afterwards, with the two linked together. That'd get very complicated though- the Reliant tank would need a filler neck for the test, but would have to be sealed afterwards cos it would be permanently pressurised by the higher mounted Pop tank. Filling the Pop tank would take forever cos the fuel would have to drain down into the Reliant tank. We'd probably have to run 2 fuel lines to the motor with a valve inside the cab to switch from one to the other, etc, etc.
So I've now decided to run the Reliant tank for the test, then remove it afterwards & use the Pop tank on it's own. We'll make up a temporary wooden bed floor, with a hole cut in it for the Reliant filler cap, then replace it later & fit the other tank. The space under the floor left by the Reliant tank could then become hidden storage space.
 


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 02, 2010, 11:08:44 PM
So back to the cradle I made for the Reliant tank a while ago. Rather than just drilling & tapping threads directly into the chassis cross member to bolt the cradle to, or welding in single captive nuts, I've tacked 2 nuts together to form a longer threaded insert, (as suggested by someone here), then welded them into lengths of tube.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 02, 2010, 11:13:26 PM
With a hole bored right through the cross member, the tubes can then be welded in place. I figure welding both ends of the tube will be stronger than just mounting them to one face of the chassis cross member.
It turned out I needed to notch the underside of the cross member though, rather than drilling it, so I've welded the ends & will finish the underside when we strip the car down & flip the chassis over to fully weld everything later.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 02, 2010, 11:17:12 PM
So now I have 2 M8 mounting holes in the chassis cross member, for the front of the tank cradle. I've flushed off the front face, but still need to sand back the back face & blank the open tube end, probably by welding a washer into it.
Next I'll do the same for the back of the cradle.


Title: Re: Manky's Pop.
Post by: Clive on March 03, 2010, 07:36:04 AM
Nice neat idea there matey!! But go on then, how did you weld the nuts inside the tube?

Clive


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 03, 2010, 10:09:11 AM
 ;D Magic.
I wound a pair of nuts onto a bolt & tacked the nuts together, then used the bolt to hold the nuts into the end of the tube. There was a big enough gap between nuts & tube to run some weld around the tube end. After making sure the bolt was still square in the tube, I drilled two holes through the side of the tube & "button welded" through them onto the nuts inside.


Title: Re: Manky's Pop.
Post by: panthershaun on March 03, 2010, 11:40:15 AM
I do hate clever kid's  ::) ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 03, 2010, 12:13:13 PM
Bet you were the one at the back of the class, not paying attention & drawing hotrods in your exercise book.


Title: Re: Manky's Pop.
Post by: Mr_G on March 03, 2010, 08:20:09 PM
Coming on nicely, Just one question. If you were to put something in the back that's heavier than say a large dog, would the chassis not bottom out on the Diff?

Cheers G.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 03, 2010, 10:05:53 PM
 ;D
I use a wide angle lens for these shots cos there's not much room to move round the truck in the workshop. It can sometimes be misleading. The chassis cross member is actually several inches behind the diff' housing. I also cut a curve in the underside of it to mimic the curve of the diff' housing. The shocks are adjustable gas units which are currently on their softest setting. They'll be wound up a bit once the bodywork's all on & we know how heavy it'll be.
There is a vague sort of plan thingy -honest. 


Title: Re: Manky's Pop.
Post by: Mr_G on March 04, 2010, 08:59:40 PM
Ah I see, it was just camera trickery. Nice job matey.


Title: Re: Manky's Pop.
Post by: twolanes on March 05, 2010, 01:07:38 PM
Another nice bit of work mate.


Title: Re: Manky's Pop.
Post by: panthershaun on March 05, 2010, 07:26:24 PM
Bet you were the one at the back of the class, not paying attention & drawing hotrods in your exercise book.

 ;D ;D ;D ;D :P :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 06, 2010, 10:56:33 PM
Rear tank mounts are the same, but slightly higher on the cross member, so I had to drill & file holes for them, rather than grinding a notch in the box section. Took ages to file the holes out big enough to take the tubes with the mounting nuts in them.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 06, 2010, 11:00:12 PM
The tubes are welded into the cross member to form another pair of M8 captive nuts.
Suprisingly, all 4 bolt holes line up & I can bolt the fuel tank carrying frame in place.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 06, 2010, 11:04:00 PM
Remember, this tank is only temporary, just to get the Pop through the test & maybe to run with for the rest of the year. After that we plan to strip the truck down for a rebuild & proper paint job. At that time we'll swap the underfloor Reliant tank for a pick-up bed mounted Ford Pop one. We'll then use the space under the bed for a secure storage box.
This will all be hidden by the side body panels.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 08, 2010, 01:00:33 AM
Loony & I spent the day today at the NSRA swapmeet in Essex, where I picked up a couple of odds & ends for the Pop.
At the same meet last year I bought an old Bakalite Ford Prefect dashboard. Lovely looking thing, full of period gauges. It's got an ashtray at either end of it. I'm a non smoker & didn't want ashtrays in my car, but you couldn't blank them off without messing up the Bakalite. Also, being brown, it clashes with the all black interior of the Pop & it'd be a crime to paint it. So I bought a fibreglass dash today for 10 quid. I can paint that any colour I want without feeling guilty, plus it hasn't got any ashtrays & only one gauge, which I think I prefer. For a tenner it's worth a play with anyway.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 08, 2010, 01:06:59 AM
A '50s Lucas rear view mirror of unknown origin with anti dazzle flip up action. 10 quid. The back matches the Bakalite dash ...which we're not using.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 08, 2010, 01:12:38 AM
And a very shiny new chrome plated Lokar handbrake lever for 30 quid. Loony stopped to chat to Scottie & Gina, (hi guys), & I got distracted by the stall of many shiny things. Before I knew it this was mine.
Nice & short, so perfect for the Pop's limited cab space & I like the push button. Thought of dismantling it & powder-coating the body black, but there'll be chrome window winders & stuff in the cab, so it won't be too out of place. I like it anyway. A bit nicer than the Reliant one we were going to use.


Title: Re: Manky's Pop.
Post by: SteveRedd on March 08, 2010, 08:26:02 AM
watch out for the shiny stuff...it creeps in and before you know it you've been out and bought a Harley  :o :o


Title: Re: Manky's Pop.
Post by: panthershaun on March 08, 2010, 10:00:44 AM
before you know it Manky, you gonna be building a
;D ;D ;D Street Rod  :-* :-* :-*


Title: Re: Manky's Pop.
Post by: VALLEYSBOY on March 08, 2010, 08:32:47 PM
looks spot on does that hand brake :) tank location is spot on too, says he who knows nout :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 08, 2010, 09:49:03 PM
We know slightly less than nowt Gareth, but can talk like we know what we're doing with the best of 'em.
A super smooth, shiney & modernised Street Rod Shaun? I think not Sir!
I fully intend to drive my truck as often & as far as possible, (though I doubt I'll be commuting to work in it), so blingy thingys will be kept to a minimum -like they used to say: Chrome don't get you home.
The new fibreglass dash propped in place. On reflection, the Bakalite one looked too posh -too refined for a truck. This looks more in keeping with the style I think. Probaly paint it gloss black with the rest of the body then add some red in the horizontal grooves, scrubbed back off till it hardly shows, so it looks old & faded, to pick up the red piping on the seats.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 08, 2010, 09:51:37 PM
My lovely assistant, Loony, holds the miror in place. By the time we've added windscreen wipers, a tax disc & my hands on the steering wheel, there ain't gonna be much screen to look through.


Title: Re: Manky's Pop.
Post by: NeilG on March 08, 2010, 10:16:22 PM
Looking good sir,at least at every Thornycroft show theres a bit more of it  :P

By god you can move fast when you want to,shouted to you at the swap meet yesterday but you ran away,you know i'm too unfit to chase after anyone  ;D

You were looking at the black Zepher/Zody sled in the car park.We were parked just across by the fence,sat by the car drinking coffee and warming up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 08, 2010, 10:26:10 PM
Oops! Sorry Neil, you should've chucked summat at me to get my attention!
This one? It belongs to Elliot from Thanet in Kent.
http://www.jackchitrodaz.co.uk/
I was on a mission- I nipped out from the queue for the entry gate to grab a snap of it. Didn't realise till later that it was parked in front of the black Gasser Consul, (forgotten the owner's name). Would've made a great contrast for a photo.


Title: Re: Manky's Pop.
Post by: NeilG on March 08, 2010, 10:41:48 PM
Nope,it was this one,if you look over the roof of it you can see us in the back ground stood behind Justines red landrover.
Tried to throw something but could,nt reach that far  ;D
Weird thing was i'd just walked back from having a look at the same car!!
(http://usera.ImageCave.com/NeilG/nsraswapmeet7.3.10manky%20260.jpg)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 09, 2010, 11:22:46 PM
Belongs to Dan of jackchitrodaz, Kent.

http://www.jackchitrodaz.co.uk/page3.php?view=thumbnailList&category=1

Loony & I were freezing by the time we left the swapmeet -every year it seems to get colder at that arena. So we didn't hang around for long in the carpark. Sorry we missed you Neil.  ;)


Title: Re: Manky's Pop.
Post by: poprodder on March 10, 2010, 11:29:46 PM
that s**te hole don't deserve to warm up!!! :D

nice dash, and shiny parts!!!! ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 11, 2010, 09:41:47 AM
I hope you're talking abut the arena & not Lunatic!  ;D Yeah, I love the swapmeet, but it's the bleakest, coldest, most windswept place in the world.
A little bit more done. I've extended the framework under the pick-up bed, that will hold the fuel tank, forward. With an extra couple of bits of 1 inch square box section added, it'll now hold the battery too. I could've just made up a sheet steel box & welded it directly to the chassis, but apart from not being able to remove it if I needed to, it's a bloomin' heavy battery & I didn't want it just sitting on the sheet. So it's supported by the box section. Only tacked together here, so now I've got to fully weld the whole frame, then make a couple more captive nut thingys to weld into the chassis to hold the front end.
After that I need to make the battery box itself, which will bolt to the framework. That'll give me a convenient place to bolt the battery earth cable to. There'll be a battery access hatch in the floor of the pick-up bed eventually. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 11, 2010, 09:43:09 AM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 11, 2010, 04:56:04 PM
Seen at the NSRA swapmeet on Sunday. Made us grin.
(Kev Rooney's the SVA guru, who's advice we're taking to get the Pop through the registration process).


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 23, 2010, 06:12:14 PM
Still messing about with the fuel tank mounts, so nothing much to photograph. So I thought I'd show you the box of bits I've just received from Stafford Vehicle Components, (I always thought they were based in Staffordshire. Not so, the company was founded by a Mr Stafford).
Anyway, I bought-
A reversing light to match the stop/tail & indicator lamps we're going to fit.
A fog light, (same as the stop/tails but with a 21 watt halogen bulb fitted).
A matching pair of 2" diameter reflectors.
A Lucas ignition switch with built in side/low beam light switch, as used on many '50s British cars.
The fibreglass dash I picked up at the swapmeet the other day already has the 2" diameter  hole necessary to fit the switch. I noticed as I was snapping these that one of the chrome light bezels is missing. A quick phone call to Staffords & they've promised it'll be in the post tomorrow.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 23, 2010, 06:40:15 PM
I also got this. Ooh, shiny stuff. I love shiny stuff!
A dual circuit remote brake servo. For those that don't know, a servo increases the pressure going to the brakes, using vacuum from the engine inlet manifold. This cost me the best part of a week's wages, but should hopefully lay to rest the only criticism that's been voiced over the car so far, namely that we're going to struggle to stop that big V8 with non assisted drums & discs.
I'm building a 50s style hotrod truck & keeping it deliberately basic so wasn't planning on having power brakes. I'd also like it to stop though. Didn't want a big servo mounted on the bulkhead in the engine bay & all the remote servos I looked at were only single circuit. The SVA regulations require dual circuit, (two seperate feeds from the master cylinder, going to either front & rear brakes, or diagonally, one front & one rear).
This unit measures roughly 15 inches long by 8 inches diameter. It has a feed in & a feed out on either end, plus 2 bleed nipples & a vacuum pipe feed in, so fairly simple to hook up. Only thing that's puzzling me is it doesn't seem to have any mounting points. Unlike normal servos that are connected to the brake pedal, this one can be mounted anywhere on the truck. Loony & I had a quick look the other day & decided we'd try & fit it in the space below the propshaft so it's coverd by the gearbox tunnel, (obviously low enough to allow for suspension travel, but not so low it'll poke out the bottom of the chassis).


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2010, 11:50:55 PM
4 mounting tabs made up & welded to the underside of the Reliant fuel tank.
Corresponding holes drilled in the support frame & tank bolted in place under the pick-up bed.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2010, 11:52:06 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 24, 2010, 11:59:13 PM
Next we need a filler cap. Loony had a rummage through his spares pile & came up with this filler neck & lockable cap, from a Sym twist 'n' go scooter. Perfect.
As this tank's only temporary to get the Pop through the registration test -& maybe run with for a few months afterwards till the end of the season when we'll strip it down for a proper paint job- we're not going to bother with a fuel gauge. So the hole left by the sender unit is ideal for welding the filler neck to.
We're going to add a temporary plywood floor to the pick-up bed, with an access hole cut in it for the filler. At this height, the cap should be almost flush with the bed floor.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 25, 2010, 12:04:50 AM
PD's Suzuki, primed, ready for some fresh paint, courtesy of Mr Lunatic.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 25, 2010, 10:11:08 PM
Now I need a feed pipe, to take the fuel from the tank to the carb. As we're not using the Reliant fuel gauge, I trimmed the gubbins off to leave a simple pipe & filter.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 25, 2010, 10:16:50 PM
Hole drilled in the tank & pipe welded in place. The filter sits about 5mm off the bottom of the tank.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 25, 2010, 10:22:59 PM
With only a short time to play in the workshop this afternoon, I then started folding up some 3mm steel sheet to form a battery box.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 26, 2010, 10:19:48 PM
Even less time at Loony's tonight, so cut the box sides & welded them all together -being very careful not to breathe in the fumes as the steel plate had some sort of galvanised type coating on it.
The welds will need smoothing off with a sanding pad on the angle grinder cos the box is a pretty tight fit in the chassis & won't drop into place with lumpy welds.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 26, 2010, 10:22:02 PM
Another new project in the workshop. A local lad wants PD & Loony to hardtail his Yam' XS650 frame. So the chaps spent an evening setting up a jig on the welding table to make sure it goes together straight & true.


Title: Re: Manky's Pop.
Post by: panthershaun on March 27, 2010, 04:02:54 PM
good to see them practicing  ;D ;D they should be ready for the Reliant Bobber when I finally get around to it  ;D ;D ;D I did mention to Loony that I might want them to build the frame  ??? ??? didn't I  :-\ :-\ :-\


Title: Re: Manky's Pop.
Post by: Clive on March 27, 2010, 08:26:10 PM
Their place really looks like somewhere I should visit!!!!! :o :o

Clive


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 27, 2010, 08:49:04 PM
Bring that Sportster tank with you when you do then please! It's pencilled in for use on that XS650.


Title: Re: Manky's Pop.
Post by: Clive on March 27, 2010, 09:05:51 PM
Sounds like an excuse to go now!!!  Woo Hoo!! :D :D

That's if I knew where it was?

Clive


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 27, 2010, 10:04:14 PM
It's a secret location, known only to a handful of trusted Monkeys & secret service personnel.
...I'll PM you the address.


Title: Re: Manky's Pop.
Post by: panthershaun on March 28, 2010, 08:10:42 AM
It's a secret location, known only to a handful of trusted Monkeys & secret service personnel.
...I'll PM you the address.

that must make me a trusted Monkey ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 28, 2010, 08:36:23 AM
Or a secret squirrel.


Title: Re: Manky's Pop.
Post by: blair on March 29, 2010, 07:45:27 AM
as long as hes not trying to be a super squirrel  :P


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 29, 2010, 11:12:42 AM
There's nothing very super about Shaun I assure you.
 -love you really Shauny.  :-*


Title: Re: Manky's Pop.
Post by: panthershaun on March 29, 2010, 03:31:43 PM
 :o :o :o :'( :'( :'( :'(


Title: Re: Manky's Pop.
Post by: panthershaun on March 29, 2010, 03:32:09 PM
 ;) ;) ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 30, 2010, 09:20:44 PM
A spot more boxetry today. I sanded down the welds on the battery box, added a little more weld to the low spots & generally cleaned it up. I now have a 3mm steel plate, virtually bullet proof box. A little over-engineered maybe, but it matches the rest of the truck.  :)


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 30, 2010, 09:24:00 PM
I then fixed it in place by drilling 2 holes front & back, drilling & tapping corresponding holes in the chassis crossmembers to M8, then bolting the box to the chassis. The battery's weight is supported by the framework underneath.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 30, 2010, 09:26:15 PM
Next job will be to make a retaining strap to stop the battery bumping around inside the box & damaging any electrical connections.


Title: Re: Manky's Pop.
Post by: terry t on March 30, 2010, 10:10:27 PM
hi andy. petrol tank and battery box looking nice. just one question on the battery box .should it have drain hole in the bottom if water from road splashes up  from wheels and vents in the side to stop battery getting hot


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 30, 2010, 10:54:42 PM
Well spotted young Sir. Yes, it should. Not finished yet. It'll have drainage holes, but probably won't bother with vents cos there won't be a lid on the box & there'll be an inch gap between the top of the box & the underside of the pick-up bed. There'll be an access hatch in the bed floor.


Title: Re: Manky's Pop.
Post by: Mr_G on March 31, 2010, 07:28:38 PM
Well spotted young Sir. Yes, it should. Not finished yet. It'll have drainage holes, but probably won't bother with vents cos there won't be a lid on the box & there'll be an inch gap between the top of the box & the underside of the pick-up bed. There'll be an access hatch in the bed floor.

I was about to ask how you would gain access to the battery after the pickup bed was fitted. Question answered. Looking good.


Title: Re: Manky's Pop.
Post by: Manky Monkey on March 31, 2010, 08:32:25 PM
Again, not much time at Chez Loony this afternoon, so I made a start on a strap to hold the battery in place. I bashed a bit of 2mm x 20mm steel into something approximating the right shape.
It fits snugly over the top of the battery & extends down the sides by 50mm. Next job will be to drill the box & fit 2 lengths of stud to bolt the strap down to.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 03, 2010, 07:23:17 PM
Box drilled & studs bolted in -& yes, I've drilled an 8mm drainage hole in each corner too. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 03, 2010, 07:29:06 PM
I'd planned to use wing nuts to hold the strap down, so I wouldn't need a spanner to remove the battery, but there's not enough room for them. As the box won't have a lid on it, Loony suggested making a pair of T handled nuts instead.
Can anyone knock me up a couple of lengths of mild steel threaded tube -say 12mm diameter by 60mm long, drilled & tapped the full length to M8?


Title: Re: Manky's Pop.
Post by: gazzagood on April 03, 2010, 11:13:00 PM
i can get ya some connectors from work on Thursday and post um to ya if that's any good to ya  (sir) but they only 50mm long with m8 hole threaded all the way thought about 12mm hexagon  :-*

gaz


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 04, 2010, 08:33:34 AM
Yes please Gazz, that'd probably do the job. They need to be mild steel so I can weld a rod across the top to make a T handle.
Thanks mate. Let me know how much I owe you please.


Title: Re: Manky's Pop.
Post by: gazzagood on April 05, 2010, 03:00:26 PM
no problem mate ill get um posted to ya thurs/fri may be galv but if you weld it as ya know keep ya nose and mouth shut ;D

gaz


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 05, 2010, 10:13:51 PM
Thank you Sir.  :-*


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 07:28:16 PM
Back at t'workshop, Loony's made a start on the side panels for the pick-up bed. If you haven't been following the plot so far, rather than just making a straight sided square box, we're using VW camper van repair panels to give it a bit more shape. Here you can see Loony's folded up some lengths of flat sheet to form horizontal struts between the frame uprights. These will give him something to tack the panels to if needed.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 07:41:53 PM
The V Dub panels flare out over the wheel arch then curve under at the bottom. We're using lightweight cycle type mudguards over the tyres, so the arches only have to step over the axle, not cover the wheels. After a bit of trial fitting, we decided the arch opening looked best cut to the same width as the tyres. So we sliced up the repair panels then Mr L cut & shut the arches to suit. Rather than just butt welding the cut edges together, he used a joddler to produce a step in the edge of one panel so that it slips under the other to create a flush joint. The overlapping edge was then drilled & plug welded, being careful to keep the heat to a minimum so as not to distort the thin sheet metal. Eventually the joint will be seam welded & with a light skim of filler, should be invisible. 


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 07:45:09 PM
The double curves of the lip of the arch couldn't be "joddled" with Loony's hand held tool, so had to be butt welded, but being shaped, they were much less prone to disortion than the flat areas of the panel.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 07:54:35 PM
From the side, the arches won't really show, but once you step to one side or the other you can see though them to the shocks & 4 bar suspension linkages underneath. That'll hopefully hint at something a little clever under the 1950s truck body.   


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 07:59:47 PM
A rare sunny day today, so time to shove the Pop out of the workshop & have a look at our progress.
The seemingly endless damp weather has added a film of surface rust to even the most recently made parts. Hopefuly it'll just buff off, but does make the truck look a bit scruffy.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 08:03:43 PM
We're happy with the look of it so far.


Title: Re: Manky's Pop.
Post by: NeilG on April 06, 2010, 08:08:37 PM
Oooh,looking purty  ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 08:13:10 PM
Only from one side Neil! Walk around the other side & it looks like a film set, mocked up for the camera.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 08:20:20 PM
You can see how far the side panels will extend below the chassis. That'll hide the fuel tank & battery box as well as the chassis rails. We've talked of extending the fronts down to meet the bottom of the cab. That would also hide the bottom 4 bar rods. On the other hand, keeping the bottom edge higher might balance out the front end panels when they go on. The bonnet sides will follow the sweep of that curve in the door panels. Not sure yet.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 08:30:58 PM
My lovely photographic assistant shows where the rear valance panel will fit. It'll hold the rear lights & number plate. I'd like to either run the exhaust pipes out through the panel, or cut into the bottom edge of it, depending how much room there is.


Title: Re: Manky's Pop.
Post by: poprodder on April 06, 2010, 09:12:38 PM
(http://www.jcsdesignz.com/import/graphics/Compliment/excellent-smiley.gif)


Title: Re: Manky's Pop.
Post by: poprodder on April 06, 2010, 09:15:11 PM
and it started like this!!!

(http://www.mankymonkeymotors.co.uk/forum/index.php?action=dlattach;topic=1879.0;attach=3065;image)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 09:19:31 PM
Scary ain't it! A 400 quid Ebay buy. I'm sure some would say we haven't improved it, but we like it & that's all that matters.  ;D


Title: Re: Manky's Pop.
Post by: Mr_G on April 06, 2010, 09:54:02 PM
Most excelent guys, looks really good. Are those wheels the ones that'll be on it when it's finished?


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 06, 2010, 10:13:43 PM
Yup. They're actually powder coated, but covered in grinding dust at the moment. The hub centres need scrubbing up & painting. We're going for a 1950s hotrod truck look. Blingy billet aluminium wheels wouldn't have been available. Hotrods were originally put together from parts adapted from other vehicles & built for speed, not necessarily looks. That came later, leading to the whole custom scene.
Front wheels are 15" Hillman Minx, rears are 16" black taxi cab.


Title: Re: Manky's Pop.
Post by: DIZZY on April 08, 2010, 08:42:52 PM
Thats gona look superb when its done,bet you cant wait to be drivin it down the road?


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 09, 2010, 09:37:58 PM
With skinny crossplys, no power steering & neanderthal front suspension/steering, it promises to be a, err...lively, ride -but yeah, can't wait! 


Title: Re: Manky's Pop.
Post by: panthershaun on April 10, 2010, 09:29:59 AM
With skinny crossplys, no power steering & neanderthal front suspension/steering, it promises to be a, err...lively, ride -but yeah, can't wait! 

Can't argue with that  ;D ;D we will have to see just how the crossplys affect the handling when we do a side by side test on them  ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 10, 2010, 01:37:25 PM
You mean a sideways test around the dirt oval.  :D
I'm not really planning on racing mine, even though Loony & I keep joking about it. I just want something reasonably well behaved that I can use as a daily driver for everything except the daily M3 commute to work & back.


Title: Re: Manky's Pop.
Post by: panthershaun on April 10, 2010, 03:09:45 PM
I didn't mean racing mate, it will be cool to see how they compare  8) 8)


Title: Re: Manky's Pop.
Post by: poprodder on April 10, 2010, 10:43:21 PM
i'm guessing i'm a wuss as i'll have IFS with x-plies!!!


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 11, 2010, 07:23:00 AM
Independant suspension?! Pah!


Title: Re: Manky's Pop.
Post by: panthershaun on April 11, 2010, 08:26:03 AM
hey Chris, I'm running  :-\ radials  :-[ :-[ :-[ :-[ hence seeing how mine and Mankys compare as we are both running beams, If i was running mine fully fenderd I would have independant on the front as well ;D


Title: Re: Manky's Pop.
Post by: voodoo on April 11, 2010, 09:47:28 AM
Do love the stance of your truck....I am tempted to either find another or track down my old A55/A60 pick up truck to give myself a bit of fun motoring......only trouble is people seem to think just because its old its worth s**t loads lol.....Looking forward to seeing your truck up close....voodoo....


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 11, 2010, 05:30:52 PM
It ain't that pretty up close mate. Still lots of bodywork to sort out & most of the chassis is still only welded on the top face -once everything's in place we'll strip it all down, (I reckon it'll only take an afternoon), & roll it over to fully weld everything.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 04:53:16 PM
With the back end more or less complete & just waiting on Loony to add the sheetmetal, I've started working my way forwards again. Before he can plan the floor & bulkhead, I need to fit any interior stuff, like pedals & handbrake etc. The bodyshell's only tacked in place on the chassis, so we'll have to start thinking about body mounts too.
The brake pedal & master cylinder are already sorted. Just waiting on Stafford Vehicle Components to supply the hanging bracket for the remote servo & we can plumb the brakes in. The brake pedal comes up through the floor, (or will do once we've actually got a floor), but we decided it was easier to make a pendulum throttle pedal that will hang from the bulkhead. Actually it'll be mounted in a piece of box section, same as the brake one, & hung from the side of the framework that loops under the dashboard. The exhaust system will run under the floor, alongside the chassis rails, so a floor mounted thottle pedal would get in the way.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 04:58:29 PM
We're trying to recycle as much of the original Pop as we can, not because we're trendy green tree hugger types, but because it saves us buying stuff & also cos it's just kinda cool to adapt & re-use the old parts. So I took the remains of the pedals, left over from making the brake one & cut them up.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 05:00:48 PM
Obviously it'd be nice if the 2 pedals are roughly the same height & end up the same distance from my feet, so I shortened the cut up bits & turned the end around to produce this.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 05:06:34 PM
Looks a bit odd turning through so many different angles, but no more so than the original did.
Then I bolted on the end plate & thick rubber "Bulls Eye" pad, supplied by Chris of "Pop Browns", to match the other pedal.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 05:12:08 PM
It needs a short arm above the pivot point, for the throttle cable to attach to, so that it's pulled when the pedal is pressed. So I re-used another part from the original Pop set-up. No idea of the pedal ratio -I tend to work by the try it & see method. The cable appears to move about 2 inches between fully closed & open so hopefully this'll work.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 05:15:17 PM
Once it's fitted to the framework under the dash, the pedal should end up level with the brake one & more or less symetrical to it, the other side of the steering column, as the pedal arm is angled out to one side.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 05:18:53 PM
We'll need to fit a throttle pedal return spring, which Pop Browns also sell, to help lift the heavy pedal to it's resting point. On my way home from Loony's place, I dropped the pedal & a short piece of box section at my mate Reg's house. With luck he'll use the lathe in his shed to produce some bronze or brass pedal bushes, plus a pinch bolt fitting to attach the cable to the pedal arm.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 05:24:56 PM
While I wait for him to do that, I'm going to re-work the steering column drop. I haven't been happy with this since I made it -far too chunky & industrial, even if it is going in an old truck.
The steering wheel sits at the right height & the other end attaches to the knuckle joints & steering box fine, so I need to re-make the drop mount to the same length as the old one.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 05:28:21 PM
I thought it had to clamp around the column, but after checking out other people's cars at shows, most seem to weld tabs directly to the column outer sleeve & bolt the drop bracket to that. So I chopped up my original clunky clamp thing & we'll weld the 2 clamp halves around the column outer sleeve. That should give us something beefier to weld a tab to.
I'll re-use the arms I made before, bolted to the same tabs under the dash, but bring them in tighter together & weld a mounting tab to the point where they meet. I'll probaly make new tabs with 2 bolt holes rather than 1, so the column can't swing from it's mount.


Title: Re: Manky's Pop.
Post by: panthershaun on April 14, 2010, 05:34:39 PM
looking good mate  8) racing ahead I see  :'( received my piggy box from Plasticpig today so off up the barn sunday for some major playing around  ;D ;D ;D ;D ;D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 14, 2010, 05:49:57 PM
Can't beat a bit of playing around in the shed Shaun.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2010, 07:32:41 PM
Old clamp halves welded around the shortened Moggy Minor steering column outer sleeve. You can see the collapsible section from a VW Beetle I added to the bottom of the column. Not required for the commercial vehicle SVA test, but not a bad idea anyway.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2010, 07:38:40 PM
That gave us somewhere solid to weld a new mounting tab to.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2010, 07:43:13 PM
Then I cut down the arms I made before & we tacked them to another tab. Next I'll cut a triangular infill plate & weld it all together.


Title: Re: Manky's Pop.
Post by: poprodder on April 17, 2010, 07:47:10 PM
got to do that on mine, but the column is nearly 18" from mounting points under dash!!! :o ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 17, 2010, 07:50:31 PM
Sheesh! Mine's 6 1/4 inches.


Title: Re: Manky's Pop.
Post by: panthershaun on April 18, 2010, 06:53:18 AM
mines using the standard mount off the parcel shelf under the dash  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 18, 2010, 08:17:01 AM
I haven't got a dash. Or a parcel shelf. Or any parcels.


Title: Re: Manky's Pop.
Post by: BikerGran on April 18, 2010, 07:30:27 PM
And you a postie!


Title: Re: Manky's Pop.
Post by: poprodder on April 18, 2010, 08:23:35 PM
i thought it was parcel farce who had no parcels just missed you leaflets!!!   lol :P     


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 18, 2010, 08:47:03 PM
 ;D The "Sorry we missed you" cards are officially known as P739s.
Personally I reckon they should say "We ain't sorry at all. It's your fault you weren't in, not ours. Serves you right for ordering stuff off the internet. If you know you're not gonna be in when we deliver it, why didn't you get it sent to somewhere where you are gonna be, you muppet"
I regularly deliver parcels that have courier's labels on, like CityLink. Presumably they take the money from the customer, then hand the package to Royal Mail to deliver? 


Title: Re: Manky's Pop.
Post by: poprodder on April 18, 2010, 08:50:05 PM
i just make the mrs wait in, unless its something i should'nt of bought then its delivered to work!!! have'nt had many parcels delivered in the past year or so though!! :(


Title: Re: Manky's Pop.
Post by: BikerGran on April 18, 2010, 09:39:35 PM
When it's really annoying is when you ARE in - but they stick the 'sorry we missed you' thing in the letterbox anyway - you know they're just trying to make up time!   (Not getting at posties, all couriers do it too!)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 18, 2010, 10:25:40 PM
Or when you hammer like hell on the door, ring the bell, wait for 5 minutes, knock again, then finally write the card out & put it through the letterbox.
Then just as you walk away they open the door & say Oh, I didn't hear you.  >:(


Title: Re: Manky's Pop.
Post by: tbone on April 19, 2010, 08:54:59 AM
Ah, it pays to be on first name terms with your postie, that way if your not in, he`ll write you a card that says something like "parcel left under the flowerpot"  ;)


Title: Re: Manky's Pop.
Post by: Clive on April 19, 2010, 12:59:35 PM
Yup!! I agree! Me and Alan are bestest friends now!!

Clive


Title: Re: Manky's Pop.
Post by: thebigdogsix on April 19, 2010, 01:43:08 PM
Totaly agree John our postie is a top guy  :)


Title: Re: Manky's Pop.
Post by: bigdarren on April 19, 2010, 07:08:57 PM
my postie has a key to the shared flat door and stash's any parcels in me upstaires coal shed  ;D


Title: Re: Manky's Pop.
Post by: poprodder on April 19, 2010, 08:19:51 PM
our postie pops in for a cupa, gets the neighbours talking!!!
good job he's a close friend :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2010, 10:07:57 PM
One of my previous partners used to be one of my customers. She lived in the last house on my dellivery. Left her hubby & we lived together for 10 years.
Back to the plot-
Mr Gazzagood very kindly sent me a couple of hexagonal threaded bars the other day. Connectors of some sort apparently, but perfect for holding the Pop battery in place. I made up a couple of T handles from 6mm rod. They'll do nicely. Thanks Gazz.  


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2010, 10:24:27 PM
Did a little more on the steering column mount. I've cut a triangular gusset from 3mm plate & welded it between the 2 arms. With the bottoms of the tubes welded & a bit of cleaning up, it should do the trick.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 19, 2010, 10:27:55 PM
Meanwhile, my mate Reg machined me a couple of bushes for the throttle pedal as well as making a neat stainless pinch bolt thingy to hold the throttle cable. Unfortunately he made the bushes in mild steel when I wanted bronze or brass. So Doc, (Twisted Patience), is going to make some more. Thanks guys.


Title: Re: Manky's Pop.
Post by: gazzagood on April 20, 2010, 07:23:03 PM
your more than welcome (sir)  ;D  just glad i could help you for change  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 20, 2010, 10:18:56 PM
They did the job admirably, thank you.
Steering column hanging bracket complete.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 20, 2010, 10:29:45 PM
I used an off-cut of the 40 x 80mm box section from the chassis to make a pivot box for the throttle pedal. The pedal itself needs to hang the same height & at the same angle as the brake pedal. So I had to rework it again. Hopefully this'll work.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 20, 2010, 10:32:02 PM
.


Title: Re: Manky's Pop.
Post by: voodoo on April 21, 2010, 02:55:36 AM
I noticed the pic of the trike with no mudguards?..what the law about running like that?...I remember I had loads of grief running my old model t without them...voodoo...


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 21, 2010, 06:18:25 PM
That's Flap's trike. Came in about a year ago to have rear mudguards fitted & is still there.
Guards aren't required for the MOT, (last time we MOT'd Flap's the tester actually went off & phoned the Ministry for advice & was told they weren't necessary). However, they're listed in the Construction & Use regulations. So your trike can pass the MOT, then you can get pulled over on the way home & nicked for not having them. I hear all sorts of versions of the consequences, ranging from fixed penalty fines, to 3 points on your licence for each missing guard. I'm not sure what the truth is.
Basically, it's up to you whether you risk running without them. Plenty of trike owners do without ever getting stopped, but I know I'd be the one that'd get nicked the first day I tried it, so I'd rather fit them to start with.
Flap now works as a lorry driver so can't risk points on his licence, so decided to play safe & add guards -eventually.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 21, 2010, 06:29:18 PM
Not easy to pick out among the jumble of stuff in the cab, but this is roughly where the throttle pedal will mount, as demonstrated by Mr Lunatic.


Title: Re: Manky's Pop.
Post by: poprodder on April 21, 2010, 09:22:17 PM
i've got three pedals in mine!!! not much room!!!
looks like your making some progress.
i thought my pedals looked rather high but after seeing yours mine seem ok.(as in look same height)
cheers chris.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 21, 2010, 09:38:22 PM
Depends how big your feet are!


Title: Re: Manky's Pop.
Post by: panthershaun on April 22, 2010, 10:03:06 AM
I noticed the pic of the trike with no mudguards?..what the law about running like that?...I remember I had loads of grief running my old model t without them...voodoo...
A mate of mine was stopped in his 2cv rod and told he risked having his car confiscated and crushed !!! and he is a coppa  ::) ::)


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 22, 2010, 11:08:06 AM
That's a bit drastic!
Really not worth the risk is it.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 22, 2010, 04:21:04 PM
My day off today. The early starts & late nights all week eventually take their toll & I tend to sleep in till lunchtime on my days off to recover. Had a few errands to run this morning, so only been in the shed for a little while this afternoon.
I've finished the brake pedal. Should do the job. Needs a return spring though. The carb has a spring that'll pull the throttle cable back to the shut position, but it needs another on the pedal to lift it up when you lift your foot off the gas. I've got some 80mm long stainless springs for the exhaust on my trike, cost about 4 quid each. So I tried one of them. Hooked over the cable clamp on the top arm, then around the bottom of the box section, it works perfectly. Result. I'll either notch or drill a hole in the bottom edge of the box to locate the spring end in. So I've ordered a couple more from Ebay. They're Ducati exhaust springs by the way.   


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 22, 2010, 04:23:23 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 22, 2010, 04:23:57 PM
.


Title: Re: Manky's Pop.
Post by: panthershaun on April 22, 2010, 04:33:47 PM
nice job  8)


Title: Re: Manky's Pop.
Post by: poprodder on April 22, 2010, 05:48:08 PM
very neat.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 24, 2010, 05:28:26 PM
I added a couple of triangular gussets top & bottom of the box section today, then tack-welded the whole ensemble to the tubular framework that loops under the dashboard. I'll eventually glue a strip of thick rubber to the inside of the box section, where the pedal arm stops against it, so that it doesn't clang every time you take your foot off the gas. Job done.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 24, 2010, 05:31:54 PM
Following PopRodder's post in his Pop build thread about swivel bearings to support the bottom of the steering column where it passes through the bulkhead, I ordered a 7/8" bore one. It arrived today. Including postage, it came to 16 quid. From bearingboys.co.uk


Title: Re: Manky's Pop.
Post by: poprodder on April 24, 2010, 09:05:43 PM
i've been fitting mine tonight!!!
excellent service from them. 
will put some pics up on my thread tomorrow.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2010, 07:58:42 PM
I haven't got a bulkhead to fit mine to yet, but it's a perfect fit on the bottom of the steering column. It's held in place by 2 tiny grub screws.
I've shortened the V shaped column hanging bracket a bit more to tidy it up. Next job is to add mounting tabs to the frame loop under the dash & hang the column in place.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2010, 07:59:36 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 26, 2010, 08:00:37 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 27, 2010, 08:41:43 PM
Steering column fitted.
I made new mounting tabs to weld to the loop under the dash & we shuffled the column around until we got the best compromise of clearance for the shaft between chassis & starter motor, clearance for the driver's hand between steering wheel & door & got the wheel sitting as square to the dashboard as we could. 
Loony's spent the afternoon clambering around in the cab, welding up as many tacked together chassis sections as he could reach. Managed to get most of it done before giving up when he ran out of places to sit that weren't red hot from welding.   :D


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 27, 2010, 08:46:25 PM
Squatting in an imaginary driver's seat, Loony tried the steering, pedals & gearchange & pronounced them all working well & comfortable to use. That's lucky then.
In a moment of boredom we uncovered the shiny red snooker ball gear knob that Doc machined for us. It's been covered in a protective layer of masking tape, so it's bound to get scratched now.


Title: Re: Manky's Pop.
Post by: poprodder on April 27, 2010, 09:22:29 PM
looking very nice, amazing the different steering wheel angles people have in pops, mines totally different with measurements from my daily.
i'm guessing theres a lot less room in your pick up. i've managed to get 2 ft  between seat and pedals.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 27, 2010, 10:10:58 PM
I can get both feet between the seat & pedals too!
I had a sit in a couple of 40s/50s American pick-ups at Derek's barbeque the other night, (the guy has an amazing collection of vehicles in his yard). I was suprised how little room there was in such big trucks -made my Pop seem positively spacious.
In that last pic, the front edge of the seat will be level with the cross member, behind the front flange of the propshaft.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 28, 2010, 08:07:40 PM
Had a quick measure today- 18 inches between the front edge of the seat & the pedals.
I arrived at the workshop late this afternoon to find Loony had finished welding as many chassis joints as he could reach, then got bored. So he'd cut open one of the tacked shut doors. There's no sills yet to tie the front & back of the cab together, so he had to add a couple of extra tack welds to pin the cab to the chassis. But now we have a door that opens & closes -just like a real car!


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 28, 2010, 08:12:04 PM
We'll add outriggers to the chassis to bolt the sills to & to support the outside edge of the floor -don't want the seats slowly sinking on one side cos there's no support under them. This is one of the fibreglass copies of my steel seats that Madron made. They'll need to be several inches higher off the floor than this.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 28, 2010, 08:13:15 PM
.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 28, 2010, 08:14:17 PM
"Unfinished Business"
Now with bonus opening door feature.


Title: Re: Manky's Pop.
Post by: Manky Monkey on April 28, 2010, 08:18:41 PM
We had a visit from Mr ByzMax today, bringing trike parts for Loony to paint, followed later by Mr Flap, who no-one's seen for donkey's ages.
Byz said Jeez, you've got a lot left to do.
Flap said Coo, that's come on a lot since I last saw it.
Very nice to chat to you both again.  ;)


Title: Re: Manky's Pop.
Post by: Manky Monkey on May 04, 2010, 11:00:57 PM