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Decided to smooth the rear panel anyway, can always stick the plate back there if I don't like it and it won't make any difference. Just have to make the decision before I go cutting the bumper to fit the number plate light to it's underneath. Anyway, got cracking today. Backed the car into the garage so I was closer to the TV and stripped it down.
http://i73.photobucket.com/albums/i2...orerubbing.jpg
Got myself one of these from B & Q. Did have a wire wheel in my hand until I came accross this.
http://i73.photobucket.com/albums/i2.../whatiused.jpg
It takes the paint off a treat with minimum mess and damage to the metal. Well chuffed with the results after a few minutes.
http://i73.photobucket.com/albums/i2...rubbedaway.jpg
I only have to fill a couple of millimeters, plus the 2 holes and since the panel is reinforced from behind I am happy to go with just fibreglass matting.
http://i73.photobucket.com/albums/i2...eovernight.jpg
Will leave that to go off before rubbing down, applying some filler and smoothing over. The 4 previously drilled holes where the plastic panel was fixed will just be welded up.
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The boot lid will also be smoothed so that involves removing the lock. Something I have not seen done very often on a saloon so here goes. Decided to go for a manually operated mechanism, so set about creating the lever for the lock mechanism.
http://i73.photobucket.com/albums/i2...nell/lock1.jpg
Had to widen the slot where the key barrel goes in to make way for 2 thin screws. Note the 2 holes drilled in the angled bracket and the buffed down screw heads and washers.
http://i73.photobucket.com/albums/i2...nell/lock2.jpg
Screws installed with washers added. Pics very blurry, sorry...
http://i73.photobucket.com/albums/i2...nell/lock3.jpg
Bracket added. I had previously worked out the rotational action required to open the lock and the position the cable would pull on it, hence the offset angle of the bracket.
http://i73.photobucket.com/albums/i2...nell/lock4.jpg
http://i73.photobucket.com/albums/i2...nell/lock5.jpg
Bolted down with the smallest nyloc nuts I could find.
http://i73.photobucket.com/albums/i2...nell/lock6.jpg
Lock installed with barrell still removed. I can still open the lock from the outside via a philips screwdriver at this point.
http://i73.photobucket.com/albums/i2...nell/lock7.jpg
This is the position of the lever when the lock is open.
Climbed inside the boot and shut the boot to check everything was ok.
http://i73.photobucket.com/albums/i2...nell/lock8.jpg
A flick of the lever and the boot opens. Not a lot of force required to operate this so will have to spring it quite heavily to counteract the resistance on the cable.
http://i73.photobucket.com/albums/i2...nell/lock9.jpg
Now, as this will be opened from inside the car the boot will just fly open as the boot springs are not dampened. So rather than fit gas struts I have just made a spacer for the LH boot spring.
http://i73.photobucket.com/albums/i2.../springmod.jpg
It's perfect just now to open the boot gracefully, but could need adjusting once the weight of the cable and plating over the lock is added.
Job tomorrow is to fit the cable and route it into the car. Will probably dig about at the scrappies again for a release handle from a Civic or Impreza or something.
Cheers,
Shaun.
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Today, sourced the bits and pieces I'd need to complete the first part of the boot release. Having to do this in 2 halves as I'd struggle to find a long enough cable and want to have a spring return halfway.
So after the weekly shop stopped in at Halfords for some gear cables and brake accessories. Having worked as a cycle mechanic for many years and being a keen cyclist, I knew exactly what I was after. The cables are teflon coated to reduce friction and are also pre-stretched, any left overs will be kept for my bike. Stopped by B&Q again for a load of washers and repair strips, oh and a plate holder.
http://i73.photobucket.com/albums/i2...nell/parts.jpg
Started by fixing the cable stop at the lock. And also a return spring which is from the plate holder.
http://i73.photobucket.com/albums/i2...ell/cable1.jpg
Then routing the cable.
http://i73.photobucket.com/albums/i2...ell/cable2.jpg
Drilling and cable tying as I go, being careful not to damage the outer skin with the drill bits as the two skins are very close.
http://i73.photobucket.com/albums/i2...ell/cable3.jpg
I have to overcome the fact that the cable needs to be loose as it will travel with the hinge but be secured to the inner panel. So have coiled it up as loosley as possible to reduce friction on the cable.
http://i73.photobucket.com/albums/i2...ell/cable4.jpg
http://i73.photobucket.com/albums/i2...ell/cable5.jpg
Adjusted the cable as required, the lock opens with only 40mm pull on the cable. I do not know how much pull the lever I will use will give, but the way I have done it, it won't matter as the front cable can be fixed to the lever anywhere. Have also formed a stop and sprung this lever to. With the rear light removed, I can reach in, push the lever and the boot opens slowly.
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Also finished off the smoothing of the rear panel and the boot lid.
Prepared the fibreglass for filler with that thing I got from B&Q yesterday. Then applied the filler. Whilst that was going off I cleaned the lock hole down to bare metal using a combination of that thing I got from B&Q, sandpaper and a sharpened small flat screwdriver.
http://i73.photobucket.com/albums/i2...nell/boot1.jpg
My loving wife kindly took the bootlid round to a mates to weld a plate over the hole, whilst I rubbed down the filler for another thin coat, then rubbed down and a quick coat of primer.
With the bootlid back, applied a thin layer of filler over the plate.
http://i73.photobucket.com/albums/i2...nell/boot2.jpg
Again, same process as before.
http://i73.photobucket.com/albums/i2...nell/boot3.jpg
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Cheers for the comments guys. Will update this thread with regards to suspension hopefully tomorrow when I get tyres that fit. Should also be completing the boot release and the rear panel smoothing.
Arrived today:
http://i73.photobucket.com/albums/i2...l/Newplate.jpg
Very chuffed with these!
Shaun.
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2nd - Boot smoothing.
Was a really nice day today so finished the boot and put all back together. Going to be using the car as much as I can this week to empty the fuel tank. So wanted it looking a bit presentable.
http://i73.photobucket.com/albums/i2...nishedboot.jpg
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3rd - Coilovers.
These arrived earlier in the week.
http://i73.photobucket.com/albums/i2...loverparts.jpg
http://i73.photobucket.com/albums/i2...l/chassis2.jpg
http://i73.photobucket.com/albums/i2...suspension.jpg
http://i73.photobucket.com/albums/i2...earfitting.jpg
Fitted the rears, no problems there, but the tyres slightly rubbed on the springs. So fitted 5mm wheel spacers and thought all my problems were over.
The fronts went on ok after a bit of confusion about the correct assembly, but my tyres rubbed by miles.
http://i73.photobucket.com/albums/i2...ll/OSstrut.jpg
Decided the cheapest option would be to try and fit the Avons that are on my Volvo. Swapped over and still rub.
Removed the tyre to see what clearance I had and it's not much.
http://i73.photobucket.com/albums/i2...mclearance.jpg
Went down this morning to try 185 wide tyres, but again they still do not clear.
So ventured home and decided to fit the original wheels.
But in having to do so, the brakes need to be changed.
http://i73.photobucket.com/albums/i2...soliddiscs.jpg
And on with the old wheels and wheel trims. And I must say. I love the look of this now........
http://i73.photobucket.com/albums/i2...l/slammed1.jpg
http://i73.photobucket.com/albums/i2...l/slammed2.jpg
http://i73.photobucket.com/albums/i2...l/slammed3.jpg
What do you think???
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Weekends progress was as follows:
First job was to remove the coilovers and driveshafts and fit the original suspension back in.....again.....
http://i73.photobucket.com/albums/i2...eshaftsout.jpg
Went to the scrappies and bought strut tops so I didn't have to keep taking the struts apart. These, along with the rears are now stored out of harms way.
http://i73.photobucket.com/albums/i2...iloversout.jpg
Removed the front end and stored parts as I went along.
http://i73.photobucket.com/albums/i2...l/wingsoff.jpg
Dashboard was next to come out.
http://i73.photobucket.com/albums/i2...l/dashout1.jpg
http://i73.photobucket.com/albums/i2...l/dashout2.jpg
And to round off Saturday disconnected the interior wiring loom, pulled it round to the front of the car so I could check that the rev counter worked. Earthed the loom to the slam panel, connected a wire from the coil to the rev counter.
http://i73.photobucket.com/albums/i2...untertest1.jpg
Started the engine with a screwdriver and hey presto a working rev counter.
http://i73.photobucket.com/albums/i2...untertest2.jpg
Well Chuffed...
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