Week 13!
Not a lot to see this week as I've been cleaning, sanding, de-rusting and painting the front end of the chassis. (The plan is to do the front end, rebuild the front suspension and then turn the car round and do the back end). It's not been the best of weather for painting and it gets quite dark in my garage. I'm using hammerite satin as it's very tolerant to multiple coats and I can put some more on next summer when it's warmer and drier. The rust is only superficial and the chassis is like a battleship. I raised the front of the chassis up on a workmate to make it easier to work on. http://farm9.staticflickr.com/8490/8...3c375cb7_c.jpg Chassis prep - front by marlinpeter, on Flickr In other news, I bought a complete set of Royale Owners club magazines from 1995 to 2009 so I'm spending hours reading all the building tips from the past! Hopefully, I'l have some more interesting pictures next week.... ...peter |
Week 14 has been exciting as I have been able to finally start bolting things back together and truly start the rebuild.
Despite the appalling weather I managed to get a few coats of paint on the chassis. It's come up looking like a new chassis so the rebuild of the front suspension can begin. http://farm9.staticflickr.com/8067/8...a9d19f35_z.jpg Chassis front end painted by marlinpeter, on Flickr http://farm9.staticflickr.com/8487/8...acd3763a_z.jpg Painted chassis by marlinpeter, on Flickr The front suspension utilises the Sierra front cross member. Here it is after cleaning and repainting. http://farm9.staticflickr.com/8344/8...f63ccf77_z.jpg Sierra front cross member by marlinpeter, on Flickr So it didn't take me long to offer it up and bolt it in position. http://farm9.staticflickr.com/8067/8...bc1b5085_z.jpg Bolted cross member by marlinpeter, on Flickr The upper wishbone bushes are Ford Cortina Mark 3. (this is a real vintage car!!). They have an outer metal casing that has to be pressed into the wishbone. I didn't fancy swapping these casin but found out that Flo-flex do a poly bush that sits inside the old metal casing. I was worried that the old rubber bushes might be 'vulcanised' to the casing but they weren't and slid straight out, leaving a nice clean hole for the poly bush. http://farm9.staticflickr.com/8481/8...c7d43281_z.jpg Front upper wishbone bushes by marlinpeter, on Flickr http://farm9.staticflickr.com/8341/8...d82a2213_z.jpg Front upper wishbone bushes by marlinpeter, on Flickr The wishbones are about 6mm wider than the chassis mounting points. The original builder had done the wishbones up tight to close this gap putting them under strain. I will put washers in here to give me some caster adjustment, just like the Sportster. http://farm9.staticflickr.com/8209/8...15b48e94_z.jpg Front upper wishbone bushes by marlinpeter, on Flickr http://farm9.staticflickr.com/8480/8...2b2818ee_z.jpg Front suspension - trial fitting by marlinpeter, on Flickr As previously mentioned, I want to fit a power steering rack. I've now got a column extension piece off a Mark 2 Granada which is the right length but just fouls on the chassis. http://farm9.staticflickr.com/8487/8...341aa114_z.jpg Power steering issues by marlinpeter, on Flickr It also just touches the upper wishbone bush which is more of a consequence of using the poly bushes. http://farm9.staticflickr.com/8485/8...38a47b9c_z.jpg Power steering issues by marlinpeter, on Flickr A small modification to improve the clearance from the suspension support to the power steering rack extension. http://farm9.staticflickr.com/8486/8...a96a4cba_z.jpg Steeering extension clearance by marlinpeter, on Flickr Next weeks plan is to complete re-asembling the front suspension and turn the car round so I can start work on the rear suspension. :smile:......peter |
Hi Peter
Really enjoying your build, you are going to end up with a fantastic car. You spoke of IVA earlier in your thread, is that because it is not registered correctly ? regards Roger (Tribute Build ) |
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glad you are enjoying my updates! It will need IVA because although the car was started in 1994 it was never finished by the original builder so has never been registered on the road. But I knew this when I bought it so was expecting to have to go for IVA. It should be interesting, (and the extra cost is a PITA) but there shouldn't be anything insurmountable with a little thought and planning. :smile:....peter |
Week 15 - great progress this week (mainly because the weather's been too crap to do anything else!!)
I've re-assembled the front suspension sufficiently to be able to wheel the chassis out of the garage and turn it around to work on the rear end. I've still got a few things to do like fit new shocks, lock nuts and swap that track rod end which is on the wrong side in this photo. The power steering rack is also a tad too long so I need to shorten it or fit the track rods from the manual rack which are 2cm shorter than these. I've ordered a Granada Track Control Arm which are rumoured to be a bit longer than the Sierra TCA's to see what that does to the suspension geometry. http://farm9.staticflickr.com/8202/8...a701de0e_c.jpg Front suspension - rebuilt by marlinpeter, on Flickr So I've now turned the chassis round so that I can refurb the back end suspension http://farm9.staticflickr.com/8489/8...ac0e6604_c.jpg Back end before dissmantling by marlinpeter, on Flickr I then started dismantling the rear suspension and transmission.... http://farm9.staticflickr.com/8345/8...bd6ed1b4_c.jpg Rear hubs dissmantled by marlinpeter, on Flickr http://farm9.staticflickr.com/8489/8...4d50d4c7_c.jpg Hub removed by marlinpeter, on Flickr http://farm9.staticflickr.com/8209/8...f5500ccb_c.jpg Rear hub and back plate by marlinpeter, on Flickr http://farm9.staticflickr.com/8343/8...ebfbe4ca_c.jpg Progress so far by marlinpeter, on Flickr I've also been having fun taking apart the drive shaft CV joints... http://farm9.staticflickr.com/8209/8...247ed09f_c.jpg Drive shaft - CV joint by marlinpeter, on Flickr http://farm9.staticflickr.com/8485/8...84f30b71_c.jpg Ford CV joint by marlinpeter, on Flickr There is very liitle sign of wear in the joints so plan to re-use them with a repaint and some new boots and fresh grease http://farm9.staticflickr.com/8479/8...593bc598_c.jpg Ford CV joint by marlinpeter, on Flickr (I love that last photo of the ball bearings :smile:) The joints are now being painted and I have four nice new rubber boots and CV grease. I've now got lots of bits to refurbish and repaint and then I can get back down the lock-up to finish removing the rear suspension and painting the chassis. Lots to do...... :smile:....peter |
Good work Peter. Lovely finish on the chassis. Sprayed or brushed?
Also good to see progress despite the cold. "By endurance we conquer" (Shackleton). |
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If I wrap up well and wear gloves (mechanics) I can do about 2 hours down at the lock up before nipping home for coffee, lunch, warm up, etc :lol: |
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Should have some picture of my bike engine rebuild soon. There have been some - err - issues to sort out.... Robin |
Indeed, nice pics :D excellent progress :)
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Its not to bad, just keeeeeep moving! Plus I've had 25 yrs of practice!
Have you considered buying a small compressor? With what you have spent on Hammerite you could have bought one, a cheap spray gun, 10 quids worth of paint and still been better off! Oh yes, nice balls! |
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I do have a small generator but a died a few years back and I've not spent any time fixing it as the noise used to drive me mad. You're probably right but the spray cans are just so convenient. ...peter |
Spotted this one on ebay for sale:-
http://www.ebay.co.uk/itm/ROYALE-SAB...item35c26ff630 |
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The interior on this one does look very nice and the high level brake light looks like it's made for the car. I've added the pictures to my scrap book of ideas :smile: |
Peter
Have you seen this one with some jaguar style mods... http://www.ebay.co.uk/itm/2710887375...84.m1423.l2649 John |
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The other red one has a long way to go to catch up, especially as its slush drive. |
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yes, I've seen this car advertised on ebay and the ROC website. In fact, it is one of three cars I considered when buying my car. I'm not sure I like the 'jaguar' like modifications, but others no doubt will like the style. It wasn't painted when I was looking into it and it will still need IVA and registration as far as I know. As far as I can remember, the current owner is not the original builder and I don't know how long it has been 'in-build'. I think the risk of buying a 'nearly finished' kitcar is you don't always know the full history and what has been done or not done during refurbishment. Also, rubber seals in brake cylinders and shocks, etc can deteriorate without any use and dry up or go hard, which is why I'm treating mine as a complete build albeit with the 'donor' parts already in place. ...peter |
OK, enough about other cars, here's my week 16 build update.....
I nipped down to the lock-up this morning and removed the final few pieces of the rear suspension. An hour later and I was left with this pile of bits... http://farm9.staticflickr.com/8358/8...080dac43_c.jpg Rear suspension by marlinpeter, on Flickr They're loaded up in the back of my car at the moment waiting to be cleaned down and repainted. This is a big milestone as, apart from a few measly brake lines, that completes the dismantling of the car; so everything now on is building!! :smile: Which leaves the rest of the chassis free to be de-rusted and repainted. http://farm9.staticflickr.com/8219/8...7df35914_c.jpg Rear chassis by marlinpeter, on Flickr I've cleaned up the tag on the diff final drive unit..... http://farm9.staticflickr.com/8202/8...1df36db1_c.jpg Diff. tag by marlinpeter, on Flickr This tells me that I have a non-LSD 7.5" diff built on 28th April 1992 with a 3.91 ratio. This is a little on the high side but might be OK with 15" wheels and some high profile tyres that suit this style of car. :smile:.......peter |
Hi Peter
I've been following this build .................... very well done and informative. I'm a complete novice when it comes to building a kit car; It's been a "dream" of mine for some years and 2013 will be a decisive year for me in that regard. I am very interested in the Royale Sabre but I am also looking at the idea of an MX5 transformation. We'll have to see how things develop. However, my question is in regard to what you use to "clean up" the chassis and other parts as I have never done this before? Also, although I am OK about Hammerite I notice that they have a variety of options including a waxoyl product designed for protecting a chassis and general underbody. Is that what you have been using? |
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