C19BJS, Another Rally Car Build/Rebuild!

[boffer8]

Hi All,

as many of you know me, you'll know of C19BJS my old red clubsport, club competition nova i built as a test bed for my next nova build, and as the old red shell has met its requirements and the old rust had eaten into her to far it was time to strip her and start the build of the new one. Some of you know i have been doing it for the last year or so and as i have some spare time over the festive period i thought i would make this thread and show you are where i am and what ive been upto.

First of all, here of a few pics of the old red motor i used, and how it ended up before it went to the scrapyard in the sky to join some of its mates ;)

http://i381.photobucket.com/albums/oo255/boffer8/autotest_zps033cb873.jpghttp://i381.photobucket.com/albums/oo255/boffer8/Normans09_zps922d4c20.jpghttp://i381.photobucket.com/albums/oo255/boffer8/uniroyal09_zps600ebd9d.jpghttp://i381.photobucket.com/albums/oo255/boffer8/normans2011_zps0b06b505.jpghttp://i381.photobucket.com/albums/oo255/boffer8/novapvs1_zps4c5e36af.jpghttp://i381.photobucket.com/albums/oo255/boffer8/novapvs_zps0785b827.jpg

[novarally]

Looking forward to seeing the new build Ben.

[boffer8]

So this was the shell that i had in storage for the last 5 years to use, a 20 odd thousand mile MK2 nova spin. and so the strip down began.

http://i381.photobucket.com/albums/oo255/boffer8/IMG00473-20110423-1435_zpsf3bc785b.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG00472-20110423-1435_zpsb08e3a6d.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0372_zps21aa1cab.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0374_zps0e7dc3e6.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0376_zpsf1d94d73.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0379_zpsce2770c4.jpg
http://i381.photobucket.com/albums/oo255/boffer8/IMG_0430_zps82a5baab.jpg
A few little rust spots found on the strip down, not nearly as bad as i had thought it would be, stood outside with a tarp over it for 5 years!

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0426_zps3f8626ca.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0425_zpsb4ce74b5.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0428_zps01d1289a.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0429_zpse500481a.jpg

Then all ready to get stripped of all paint, seam sealer and anything else to get it to bare metal.

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0422_zps1b34a151.jpg

[boffer8]

So while it was away, i went to the task of making the spit to allow me to easily rollthe shell over to make the welding and metal work on the shell a lot easier, this is what i came up with:

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0693_zpsf0989afc.jpg

and the following weekend went to collect the shell and then bolt it on to these to let the main work begin.

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0574_zps7fa82955.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0575_zps7b35e3f0.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0707_zps7a5146a1.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0706_zps6ba2e57e.jpg

And a close up of the finish of how it came back from the strippers:

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0576_zpsdcba2955.jpg

and loving the spit, makes life so much easier in a tight garage!

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0808_zps10ea69f6.jpg

[boffer8]

So after i got it mounted it was bracket removal time:

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0810_zps1d4e48fa.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_1023_zps3f0f1f56.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0812_zps290e98f1.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0814_zps0e1840d5.jpg

There was some severe rot behind one of the front turrets so drilled out the spot welds, peeled back the outside chassis leg and made a new one fitted it then put it all back, good as new ;)

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0854_zps453ce679.jpg
http://i381.photobucket.com/albums/oo255/boffer8/IMG_0857_zps31dd6dae.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_0900_zpsdbf0a6ef.jpg

[boffer8]

Then it was a case of flipping it over to start on the seam welding, skidding and fitting the hockly strengthening kit to the shell.

http://i381.photobucket.com/albums/oo255/boffer8/IMG_1716_zps8e7594ba.jpg

and then a case of flipping it back over and more welding and welding and welding.....

http://i381.photobucket.com/albums/oo255/boffer8/IMG_3113_zps9a2eefe0.jpg

and sealing all the holes that are no longer required in the bulkhead

http://i381.photobucket.com/albums/oo255/boffer8/IMG_3115_zpsb7b9d532.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_1021_zps2ec92f65.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_3114_zps91a0d928.jpg

and the never ending job list

http://i381.photobucket.com/albums/oo255/boffer8/IMG_3165_zpsfc99b993.jpghttp://i381.photobucket.com/albums/oo255/boffer8/Mobile%20Uploads/photo4_zps0587e6ee.jpghttp://i381.photobucket.com/albums/oo255/boffer8/Mobile%20Uploads/photo3_zps8c691bb7.jpghttp://i381.photobucket.com/albums/oo255/boffer8/Mobile%20Uploads/photo1_zpsb688a10f.jpghttp://i381.photobucket.com/albums/oo255/boffer8/Mobile%20Uploads/photo1_zps9c3ef09a.jpg

Getting there now

http://i381.photobucket.com/albums/oo255/boffer8/Mobile%20Uploads/photo2_zps7ebfe9e7.jpg

[boffer8]

One of the hardest jobs on the whole shell, not perfect but i can clear it up before it goes back to be coated:

http://i381.photobucket.com/albums/oo255/boffer8/IMG_3448_zps727398e5.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_3450_zps89f4ba62.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_3449_zps49b7ca62.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_3452_zps7bfb01ca.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_3451_zps814bca72.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_3454_zpsaadd9122.jpghttp://i381.photobucket.com/albums/oo255/boffer8/IMG_3455_zps7fc742e6.jpg

Done and dusted, thank god for that

http://i381.photobucket.com/albums/oo255/boffer8/Mobile%20Uploads/photo1_zps2bfdf8b2.jpg

[boffer8]

And thats pretty much a years work in a few posts, with me only managing to get a weekend a month if im lucky to work on the car its been dragged out with the nature of my job, but hopefully can get moving on it a bit more this coming year, got lots of little bits done at work some photos of that coming later.

Just about ready to go back and get coated now and then for the cage hopefully in feburary (fingers crossed).

[Gibbo]

So while it was away, i went to the task of making the spit to allow me to easily rollthe shell over to make the welding and metal work on the shell a lot easier, this is what i came up with:

http://i381.photobucket.com/albums/oo255/boffer8/IMG_0693_zpsf0989afc.jpg
looking very good mate.
where did you get these from mate?

[mk1nova_rich]

Looking good Ben :thumb: its gone very rusty after bare-metalling it...I'd have been tempted to give it a flash over with etch primer

[bazzap8389]

Nice update, plenty of work done!

what mount have you used on the rear turrets? Did you buy the circular turrets or make them from scratch?

[Rickyb]

Love this keep up the good work.
Rick

[boffer8]

Gibbo: the frames I made from scratch as I couldnt find anything that suited what I needed as the garage roof is quite low

Rich: its just surface and comes off easily, they will reprep and bare metal it again before its coated

Bazzap8389: the mounts are copies of ones from hockly's that I did at work

Getting on slowly, got the wooden rolling frame modified to put the shell back on and get it back for coating in january hopefully.

[8valve-craig]

Wow, I wasn't expecting that. Very good choice to get it stripped, If I build another that's the way I'l go.

Good luck with it, shall continue to watch.

[philip]

Fair play matey. Looking good. Cant beat stitch welded shells :) whats planning running gear wise?

[tomfromdelmonte]

top work with the turretting, makes me wish i'd attempted it.

[boffer8]

Well all loaded up and taken back to the coaters today, 2 weeks and then back to pick her up, can't wait!! Conditions not the best to take her today so got her all sheeted up! Couple of pics of the welds too that I'm well happy how they have come out with

http://i381.photobucket.com/albums/oo255/boffer8/6C5E859B-29A5-4BD2-9BBA-E845DB90D8F5_zpsifwywqbh.jpghttp://i381.photobucket.com/albums/oo255/boffer8/6CA3D5D7-357B-461B-B924-EE478CE6A291_zpsngbkini5.jpghttp://i381.photobucket.com/albums/oo255/boffer8/E6359D1F-C68F-4C0E-97F7-F3ACB5FC9FC0_zpsztgfj0xb.jpghttp://i381.photobucket.com/albums/oo255/boffer8/68FCFE83-80B6-4556-9F1D-084C1FAD4E48_zps03ghxmdv.jpghttp://i381.photobucket.com/albums/oo255/boffer8/1945B021-515E-4BBF-BD69-75DC3A4B0AC0_zpsofso1gpq.jpghttp://i381.photobucket.com/albums/oo255/boffer8/74A70BF5-B4CA-47FF-9F3C-24DFDF4C359C_zps4syfswis.jpg

Plus all the scrap I cut out when I did the rear turrets, some weight in those like with mostly 3 and in places 4 layers of steel

http://i381.photobucket.com/albums/oo255/boffer8/902AE0A0-BAA8-4BC1-9CBC-A3B08604F7B5_zpsmaroo8f6.jpg

And a lovely yet ready for treatment lotus cortina ready for treatment

http://i381.photobucket.com/albums/oo255/boffer8/FE9649A8-86E8-4C03-B7D6-4B495D7AE0BB_zpsylih6rh1.jpg

[boffer8]

Well after a couple of weeks the nova was collected after having been treated to a nice bath and phosphate coating followed by a lovely final E-Coat to make everything all lovely and protected.

http://i381.photobucket.com/albums/oo255/boffer8/168192F6-1D2D-4CB8-B22E-3E0FB9BB19AB_zpsjx18mpm7.jpghttp://i381.photobucket.com/albums/oo255/boffer8/7EB3735F-7261-4EF9-A4EB-B9B1F8BD0560_zpshykmugie.jpg

Thinking she looks lovely now and ready for the cage to go in before then having that primed. Then it's the dry bill stage!! Went to pick up my new door today, many thanks to Rich (nova sport) for holding on to it for me, will go very nicely on this!

http://i381.photobucket.com/albums/oo255/boffer8/A8231733-1B3A-4B31-9A64-EE5627160352_zpszxuum0yj.jpg

[gary_126]

Great build! where did you get it stripped and coated? Are you happy with it? Heard so many horror storys about this process.

A new door on a rally car, your mad! Keep the updates coming.

[dgbnova#1]

Looks good just need a drivers door now lol
as above who did your strip and e coat etc

[boffer8]

The strip and coat was done by the same people who did colins hill climb car, paintstrip.co.uk is the website I believe, to be honest the whole process has been great and had no issues with any of it, the final finish speaks for itself, it's awesome and I'm dead happy with it! At least now i know this she'll is rust free and protected for a long time. The new door was cheap and not many of them left so grabbed it, I have another door to use so I can choose at the time what's best to use and go from there. I just hope I can find a mint drivers one now, if not new but thinking I'm hoping for too much there!!

[dgbnova#1]

I've got a cracking drivers door here will get some photos if your intrested

[mk1nova_rich]

Looking good Ben, I take it its gona need redoing after the cage is in?

[boffer8]

Aye pal send them over I'll have a look see! No rich, they just remove the paint where they need to put the cage in, same as any normal cage and then it gets a primer coat on top of everything, job done then

[kevster]

Nice build bud .

[craig green]

Good work. Why the mint new panels on a 'Rally car'?