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Print Page - Time for another project

The Purvis Eureka Forum

General Category => SHOW US YOUR RIDE => Topic started by: The Green Reek on Wednesday, 18 September, 2019, 09:24:12 PM



Title: Time for another project
Post by: The Green Reek on Wednesday, 18 September, 2019, 09:24:12 PM
I picked this up earlier this year from a un-named presidential source.
This is a google album. I couldn't login to the old photo share site.
Sorry I can't embed these into the post.
This will give you a good idea of the starting place for this one.
I'll post some more pics soon.
It's had glass work done on body and lower body. Just finishing roof.
Painting will be when its warmer.
Haven't even looked at mechanics yet. That's the easy part.
Note the use of angle grinder crack removal. Not to mention the silicon and packing tape holding it together.
Album:
https://photos.app.goo.gl/u8hBkAgPEUqpDXX48
The next batch of pics will show you what 6 litres of poly resin, 5 litres of epoxy resin and 4 litres of epoxy fairing can do.

Peter


Title: Re: Time for another project
Post by: The Green Reek on Sunday, 22 September, 2019, 01:44:46 PM
OK This is the Car arriving and starting the project.
The Escort motor is coming out and a Subaru 1.8 twin carb going in.
Note the excessive number of straps on the car. Nothing was bolted down.
The boat winch makes doing the job alone possible.
I had a set of dolly wheels from a Mustang project that worked great on the body so I could move it around.
https://photos.app.goo.gl/dMGSnmHgZzNPMBw19

Peter

PS. The Escort motor and gearbox with adapter as well as the hydrolic system are up for sale.
PM Me is interested.


Title: Re: Time for another project
Post by: The Green Reek on Sunday, 22 September, 2019, 05:06:58 PM
Lower and small bits.
The lower sections of the car were my starting point.
Lots of damage. Mostly deliberate.
It appears the person who took the car apart years ago didn't own spanners.
Every screw and bolt hole was torn off. In some cases there were 5" sections of glass missing.
There was a 3' tear down the under car front piece. Right through a compound curve.
The poor old elephant ears may have been the worst and needed the most time to get back to solid.
https://photos.app.goo.gl/NU39QXzBi7xaaFpV6

Peter


Title: Re: Time for another project
Post by: The Green Reek on Sunday, 22 September, 2019, 05:26:54 PM
Tub Repair
I mentioned my dollies from a Mustang project.
Well they were built long on one side to allow me to lift the mustang onto its side.
That worked great on the Eureka as well and allowed me to access and repair all the damage on the underside of the main body.
Starting with the tub and front. First job was to fill most of the 87 holes that had been drilled into the front tub area.
Don't know yet where I want holes but I'm sure I don't want 87.
Placing a matting repair from the underside allowed me to fill the holes with matting and micro glass beads with poly resin.
Of course every hole has to be enlarged and ground with a 1-2cm taper all around to allow the matting to take.
This was also a chance to try out my Epoxy fairing mix on the front cracking.
Epoxy is much harder, much more expensive and much slower drying than poly so I saved the epoxy for bits you can see on the finished project.
Using a dremel I ground the gel coat back to mat in a 1/4" V following the cracks.
The results impressed me enough to use this technique on more sections of the car.
https://photos.app.goo.gl/a4ZRU1mvGBgcYyrU7

Peter


Title: Re: Time for another project
Post by: The Green Reek on Thursday, 26 September, 2019, 08:42:49 PM
Petrol Cap
The original petrol cap looked to bet an ill fitting Holden something.
This is a Honda CBR cap fitted to whats left of a Honda tank.
https://photos.app.goo.gl/pHDNGYsNrT6Kd3Zd7


Title: Re: Time for another project
Post by: The Green Reek on Thursday, 26 September, 2019, 08:59:19 PM
Left Rear Quarter
I've done this one in detail as it is typical of all 4 quarters of the car.
It has had a serious hit.
Bad gel cracking and some minor damage to the underlying chop.
All of the gel coat had to be removed from the cracked areas.
Note: I stopped just short of the hard edge so I could retain the original shape.
Re-enforcing mat to the underside.
New mat to the carved out areas to build the height up again.
The cracks that ran through the edge were ground out and fairing added.
The shape of the car didn't suffer at all.
https://photos.app.goo.gl/t9rMg8MAFERtpNGF7

Peter


Title: Re: Time for another project
Post by: The Green Reek on Thursday, 26 September, 2019, 09:14:59 PM
Rest of the Body
These pictures pretty well tell the story.
All quarters had suffered a fair amount of damage.
Left front was unique as the majority of the damage was done by the previous repairer.
It probably had some cracking but he attacked it with an angle grinder and cut right through the guard for about half its length.
A lot of underside repair on this to build up guard strength.
I think the repair was about 7 layers thick in the end.
Sharpy marks are low repair spots between fairing coats.
I usually did at least 3 fairing coats with a sand off between before I was happy with the finish.
https://photos.app.goo.gl/xBLHfxvni72PYGJt6

Peter


Title: Re: Time for another project
Post by: Gregory on Saturday, 28 September, 2019, 06:37:08 PM
You got yourself a pretty full on project, Peter.. The rear quarter repair job looks pretty good, well done.


Title: Re: Time for another project
Post by: shonko on Friday, 04 October, 2019, 07:16:15 PM
Looking good Peter, will this one be at Port Macquarie  :o

I thought I saw a dust cloud north of me recently, must have been you sanding away in the shed.  ;D

Shonko

PS, I am sure a lot of people are missing out on this build. You might want to put it on the Facebook page. 


Title: Re: Time for another project
Post by: The Green Reek on Monday, 07 October, 2019, 09:29:23 PM
Hi Shonko
Not Port Macquarie but Gipsland for sure.
Just the Green this year.
This one isn't a keeper though, just a project.
You're not wrong about the dust. So much gel coat. Everything is red.
I have been playing with colour.
It will be a candy. Probably deep red metallic. Hope to put some samples up soon.
Roof is pretty much done. I'll use it for a colour test.
I'm not on any fancy facesnap or twitbook. You'll have to let them know for me.
Thanks
Peter


Title: Re: Time for another project
Post by: The Green Reek on Saturday, 12 October, 2019, 08:22:44 PM
Roof and Ears
The Ears/scoops took a lot of work which I didn't document well - sorry.
As they were just ripped off the car with a lever they were broken and cracked quite badly.
I had to give up on rescuing the front lower cross arm as they were basically non existent on both.
I'll make up for that with new mesh before they go back on.
I had thought initially that the roof required little work.
I was wrong.
It is an incredible pain to remove years old silicon that had been liberally slathered all over the place to hold windows in place.
No silicon can remain if you want paint to hold.
Both aluminum (US spell check) quarter window arms had been broken off so their mount point were no existent and had to be rebuilt.
Not to mention another couple of dozen holes to get rid of.
This is where I started to look at my colour.
I had experimented with various dyes and perls.
I finally settled on a blood red dye on a lightning silver base (Baslac).
The copper looking top is due to using a base binding layer from Baslac.  
Same dye and same number of layers - Just too thin.
I ended up tossing that in favour of a clear coat colour base with dye added. Usually 5 - 6 thin layers deep.
With under coats and 2K top coats, its about 12 coats deep to get the colour I wanted.
https://photos.app.goo.gl/ctGYBBxPZgvp4srX6

PS. I've include a picture of the roof center section. This was supposed to be gel coat. NOT.
You must remove blacks from under metalic paints. They will eventually boil and bubble in the ozzy sun. It may take years but it will happen.
I'm still making up my mind as whether to make it black like the original or red to match the new top. Thoughts?
PPS. Black is a lot cheaper and true to the original car.

Peter


Title: Re: Time for another project
Post by: INSTRO on Sunday, 20 October, 2019, 07:21:39 PM
I am taking notes and going through forum info , forgot to to have a look . Richard the Second.


Title: Re: Time for another project
Post by: The Green Reek on Monday, 21 October, 2019, 06:33:04 PM
On the way back from the AGM. Awesome weekend thanks Graham and co. This reek now has linak lifters but i might have to sleep in it for a while.


Title: Re: Time for another project
Post by: shonko on Thursday, 31 October, 2019, 07:34:59 PM
It was great to catch up Pete. Looking forward to seeing you next time. Hopefully for the Picnic at Hanging Rock in February 2020  ;)

The colour you are achieving on your project is amazing. Congrats.

Shonko

PS - I have stolen all your images on this forum and I will post them on Facebook. So keep them coming. Cheers........more scotch did I hear you say?? :O


Title: Re: Time for another project
Post by: shonko on Thursday, 31 October, 2019, 07:51:00 PM
FYI, this is the post on FB with your photos

Hi All, Pete "Greenreek" has given me permission to share his project pics here.......he doesn't FB. I have asked him to keep the photos coming, and I will periodically post them here for all to follow. I think it gives some great information for the DIY warrior working in his own shed.... garden.... veranda...and knowing Pete probably the dining table. All of which is a-ok when you are living in the 'dog house'!! BUT, don't worry access to the dog house is easy when the roof lifts up and down on your new actuators!!


Title: Re: Time for another project
Post by: The Green Reek on Thursday, 31 October, 2019, 09:27:50 PM
Thanks Shonko. Don't ever mention the Scotch again  :-[. Told Cathie its all Mark's fault.
Spent the day after I got back on my "hard to start when hot" reek.
Turned out to the crappy points. At full open I barley had 3 thou. cold and that was adjusted to the max.
Fixed now and happy.
Also got rid of that crappy GT40R coil and went for a non resistive one so I've got a lot more start juice now.
Started a production line of lower bits for paint prep.
Hope to have paint and pics by monday.
Started looking at dash and electrics too.
Thinking about an automatic battery disconnect system while stored.
Can't count how many times I've forgotten to disconnect after a drive and gone back 4 weeks later to no battery.
Of course I do run more standby computers than most.
Peter


Title: Re: Time for another project
Post by: The Green Reek on Tuesday, 05 November, 2019, 07:42:36 PM
Black Bits
The lower car pieces were repaired quite a while ago but that was structural not finishing.
So it was finally time to get them painted.
I usually start with a thin undercoat.
This helps identify cracks and pin holes that you miss after the initial sanding.
A bit different from how you'd do a steel car.
You can see on the lower section that I had a number of holes that were hollow and went into the matting.
These are probably imperfections from the original gel coat.
The best way of dealing with these is to use the dremel and make them larger and much easier to fill adequately.
That is generally true for most pin holes.
After repairs and sanding I will do a much thicker undercoat to assist with any sanding swirl marks that may have been left.
After another sand I'll finish with a flow coat to give a smooth surface.
Time for the black.
This is a Baslac gloss black applied in 3 layers.
Pieces came out OK.
They will then get a light 1200~1500 grit wet sand where ever I find marks before a 2K top coat black will be applied.
An aluminium skid pan will be added to the center of the front piece. On my other car they usually only last about 3 years.
Finally the bits that face into the wheel arches will get a thick under chassis paint to protect them from stone chips.
https://photos.app.goo.gl/gaqP2NQRBSuD4Ryq7
Peter


Title: Re: Time for another project
Post by: shonko on Monday, 11 November, 2019, 02:05:37 PM
Hi Peter,

Posted on FB  ;D

Keep them coming, looking good!!

Shonko


Title: Re: Time for another project
Post by: The Green Reek on Friday, 22 November, 2019, 06:43:46 AM
Sorry its been a while.
Pics here -> https://photos.app.goo.gl/3M3FRj8ydnTrDKph8 (https://photos.app.goo.gl/3M3FRj8ydnTrDKph8)
Got busy last weekend with smaller bits.
My new mirrors finally came in. Pic1.
The black bits I'd done where in base coat and it was time for a 2K top coat.
With professional paints a base coat will never fully harden, A bit like polyester resin without a wax component.
So a decent rub back and apply a 2K black top coat. Next 3 pics.
The difference is fairly significant.
Finally it was time to get rid of smaller pieces (including new mirrors) that needed red.
Just the body and bonnet left.
Peter


Title: Re: Time for another project
Post by: shonko on Thursday, 28 November, 2019, 01:32:09 PM
posted on FB  ;D


Title: Re: Time for another project
Post by: The Green Reek on Monday, 09 December, 2019, 10:47:17 AM
Last post on this before Chrissy.
Finished the last of the red bits (Bonnet)
Car's now gone into the shed for prep.
Been pretty slow painting because the temp here hasn't been above 15 for a few weeks.
Making up for it now. 41 today.
Pretty much prepared for electrics now with all my bits and pieces coming in.
Custom Infrared proximity alarm designed and ready to test.
I am keeping smart electronics to a minimum though.
Should paint before new year.
Peter

Merry Christmas or whatever you believe in.


Title: Re: Time for another project
Post by: shonko on Thursday, 02 January, 2020, 07:45:01 AM
Happy New Year to you and yours!

Any updates on project progress?

Shonko


Title: Re: Time for another project
Post by: The Green Reek on Thursday, 02 January, 2020, 01:36:29 PM
Hi Shonko, same back.
Been a slow break. Too many cars at home with kids coming back so not much room to work.
Plus its been pretty hot in the shed. Northern Vic has been quiet on the fire front but I hope everyone was OK through this period.

OK now for the dumb news.
Photo's here - https://photos.app.goo.gl/VpHM4jakrdsgRwBc9 (https://photos.app.goo.gl/VpHM4jakrdsgRwBc9)
I decided it was time to work on the engine. (EA82)
It had a tappet noise when I bought it and as per Cyco's post and suby forums this is nearly always caused by bad seals causing low oil pressure.

So armed with new main seal, cam seals, tension rollers, idler, oil filter, oil sender, oil pump O rings, plugs and timing belts I set about a minor tune.
Pic 1 was where to align the Cams for disassembly. Note opposite cam is 180 degrees out.
This isn't TDC but rather a mid point for all pistons to allow valve movement without the terribly clunk sound when valves and pistons meet.
The Suby manual and forums talked extensively about timing the cams so I wasn't overly worried about things moving while I was undoing tight bolts.
Big mistake!

I should (in my defense) say that all my boxer experience up to this point was VW type 1 and we time everything from the crank pulley not the flywheel.

Disassembly and seal replacement went smoothly but then I went to set timing for re-assembly.
Time marks in pic 2 are for Subaru bell housing mating plate and Subaru flywheel. Neither of which I have because it mates to a VW transaxle.

Oops!

Pic3 is old bits coming off.
After a couple of days I finally found a picture (Pic 4) of how to set the dissy timing which runs off RH cam and is based on No 1 at TDC. Yeah!
So I am pretty confident now that its timed OK. Plus it turns over without that clunk.
Pic 5 assembled and Pic 6 replaced bits. Still needs a good clean though.
Of course it will be another 3-5 months before I have it on the gear box to test this timing thesis.
Peter



Title: Re: Time for another project
Post by: The Green Reek on Sunday, 19 January, 2020, 08:13:57 PM
I should title this post as "Always check everything"

Still working on the chassis as I haven't swapped things around since Christmas.
I was in 2 minds about bothering to swap the transaxle out for the one that I got with the suby motor.
In the end I decided to as I could see shaving inside the bell housing so presumably the suby flywheel was a little different from stock vw.
This tuned out to be a VERY good move.

Pics here: https://photos.app.goo.gl/gdgchWsiDQWTfhna7 (https://photos.app.goo.gl/gdgchWsiDQWTfhna7)

While undoing the CVs to release the box I noticed one instantly hit mounting arms and couldn't be lifted off. Pic1
PS. That frame was added to support the Escort motor this car had - Gone - Yeh.
I removed the Axle and found that one CV end moved a little while the other CV was stuck at right angles to the shaft and had NO movement. This couldn't have driven well.
Pic 2 is me disassembling the CV and comparing to an old one that worked.
Pic 3 is the issue. CVs MUST be built correctly. There are only 3 pieces and 6 balls. Get them the wrong way around and it is no longer a CV.
The ball race is on backwards in Pic 3.
Pic 4 is cleaned and ready for reassembly. Pic 5 is assembled.
Remember I said one moved a little. Well it shouldn't have but it was built with only 4 ball bearings not 6.
I couldn't source the correct bearings locally so I ordered a new CV (Pic 6).
Pic 7 is the horrible job of packing these with Molly grease and Pic 8 reinstalled and working nicely with the new gearbox.

So while I was already greasy and the engine was completed I decide to install it. Pic 10.
11 and 12 are a happy suby 1800 on the chassis.

Time to fix the brakes which all appear to be seized before I move it out of the shed.
I doubt I'll post on that as we all have brake stories.
My rears are Fiat 124 discs from the pads that came out.
Haven't gotten to the fronts or master yet.
Rears will only need a gasket set to be happy.
Hope the others are the same.
Peter

 


Title: Re: Time for another project
Post by: The Green Reek on Friday, 31 January, 2020, 09:55:31 PM
I said I wouldn't post on brakes.
Well Sh!t.
Everything was stuffed.
I hate brakes.
Fought will calipers for hours to get them apart to find too much rust in the cylinders.
All Rubber lines are closed off. Half the hard lines need replacing.
Did I mention I hate brakes.
Don't get me started on those Fiat things.
Lots on new bits. It will stop.
Arrrrrh.


Title: Re: Time for another project
Post by: shonko on Thursday, 06 February, 2020, 11:05:29 AM
Hi Pete,

posted latest updates on FB, thank you. BTW are you coming to Hanging Rock? If so will we see you Saturday?


Title: Re: Time for another project
Post by: The Green Reek on Thursday, 06 February, 2020, 08:10:06 PM
HI Shonko,
Thanks for that.
I'll be heading in the north gate. Rain permitting.
What time you guys expecting to enter?
Peter


Title: Re: Time for another project
Post by: shonko on Friday, 07 February, 2020, 01:26:08 PM
we are leaving my place at 8am, so we will be heading in the north end gate around 8.15am...........see you there


Title: Re: Time for another project
Post by: The Green Reek on Sunday, 23 February, 2020, 06:42:43 PM
Been a while since I've done a post so here's the little that has been started recently.
https://photos.app.goo.gl/UanX3z2DBmnAADYU6 (https://photos.app.goo.gl/UanX3z2DBmnAADYU6)
Brakes are finally done. Pic 1 shows my brand new front calipers care of Mike Motors.
Pic 2 are some of the left overs after everything went back together.
(there's always left overs - isn't always a bad thing.)

Anyway now the chassis has left the shed, the body can come back in for final paint prep.
After sitting in the sun for almost 2 months at around 40 degrees some new cracks opened up.
So all in all its a good thing to let it bake.
I'd rather find them now than when its in final paint.

So more dremil and fibre glass fairing and more sanding.
The rest of the pics are the body now ready for final undercoat.
I hope to get the body painted in about 2 weeks.
Then comes any colour correction coats needed as all the small bits where painted separately and I was only guessing at the density I wanted.
Difficult until I've got the body done. Not expecting much though.
Peter


Title: Re: Time for another project
Post by: shonko on Tuesday, 03 March, 2020, 12:27:41 PM
posted on FB today, getting exciting :D