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Go Back   Madabout Kitcars Forum > Show off your cars > Show us your Kit Cars

Show us your Kit Cars You've just taken 2 years to build your pride and joy, right? Then why not show it off here. Let us see your creations.

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  #1  
Old 28th May 2016, 14:58
89Rallye 89Rallye is offline
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Default Speedster restoration.. Y.. Oh Y.. Oh Y..

Hello everyone,

I'm new here and new although not new to classic cars earlier in the year I became new to kit cars as I became the owner of a Chesil Speedster replica which was in a bit of a sorry state.

I'm not sure exactly when it was built but she's been slowly undergoing a light restoration as and when time permits.

I actually bought Y.. Oh Y.. Oh Y.. (As she's affectionately known) from a salvage yard, after it had suffered from an electrical fire, more on that later though.

As she was delivered in all her dirty gloriness..





Right old tangled mess in here.

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  #2  
Old 28th May 2016, 15:56
89Rallye 89Rallye is offline
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So i do wonder if the previous owner was suprised that the wiring caught fire!











So there was nothing else for it but to rip it all out...





And start from scratch..





Gauge overhaul,



Im looking for a supplier for the gauge faces, failing that im thinking maybe someone who can print a vinyl transfers to re-do the faces as a sticker.
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  #3  
Old 28th May 2016, 16:13
89Rallye 89Rallye is offline
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We have no water at our lock up so havent really been able to clean the car off properly, so when the engine lid came off I couldnt resist giving it a proper buff and polish.

Blues not really my colour and a repaint may be in order in the future but if the whole car cleans up this well ill be more than happy.









and more elbow grease..










Its not perfect but a massive improvement







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  #4  
Old 28th May 2016, 23:10
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Looks like that will come up a treat. Great find.

And welcome to the forum

John
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  #5  
Old 29th May 2016, 05:04
89Rallye 89Rallye is offline
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Quote:
Originally Posted by JG View Post
Looks like that will come up a treat. Great find.

And welcome to the forum

John
Thanks John,

I'll add bits and pieces in no particular order from the last few weeks of hair pulling pleasure lol

Didn't really want to take the engine out, I knew it would run simply from the fact that someone had recently fitted a brand new exhaust system. I'd already checked it for oil pressure which was all good.

So I took the decision to pull the engine to bits in situ and give it all a freshen up, lucky I did really as the thermostat was seized solid amongst other things.

Nearly all of the tinware required repairs of some form, this stuff is available new but its pattern quality and we all know how well that fits. Since this was all genuine VW I thought it worth saving.





















After the first coat of primer I decided I didn't like the holes in the front, so went back and removed them.







No that's not primer lol



The tank and a few other bits also received the same treatment, paintings not ideal in my dusty garage but its turned out ok.









All fitted back in with new R9 grade fuel hose

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  #6  
Old 29th May 2016, 05:06
89Rallye 89Rallye is offline
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Building the longblock back up, the greys not to everyone's taste including mine if I'm honest but what can I say I got the paint for free from work and its growing on me! oh and its the only thing we had that goes with the blue











So after getting all the engine back together it fired up and was running like a sack of nuts, so on closer inspection and going back to basics it was decided to check timing and tappets.

Where I discovered...



Very lucky really, the adjuster must have been stolen at some point as there is (luckily) no where for it to go if it had just worked loose and dropped out.



So with a replacement adjuster and everything all set, she runs!





sorry probably too many photos there!! that's what being stuck bored in work on a Saturday night will do!!
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  #7  
Old 29th May 2016, 08:14
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Thanks for sharing this. You can never have too many pictures

Nothing better than seeing someone's work on a car

Dave
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  #8  
Old 30th May 2016, 02:03
89Rallye 89Rallye is offline
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Well don't say I didn't warn you!,

I'm nearly up to speed now,

While looking around for inspiration with the gauges it was hampering my progress with the re-wire. Apart from the indicators intermittently blowing the fuse all the time (I believe down to a new yet pattern switch) the wiring Is all but completed apart from said gauges and control/warning lights.

We started to have a little pre MOT poke around and things didn't appear to bad, well that was until a poke became a prod lol









So I decided to tow the car home and much to the annoyance of my neighbours do the repairs there.

It did however give me the first opportunity to give her a proper bath.



There's a few marks on the body but im hoping the paintwork should buff up nice.



Pre-wash but it also gave a nice photo opportunity with her cousin





Anyway, I built a set of rollers many years ago and im now on Mk3 version for the beetle chassis





I did however fail, when I do this on my own I use a large porta jack but I found that with the fibreglass body the car actually didn't weigh enough to roll over and just kept sliding across. I guess I need more mates as I'm sure two/three of us would simply be able to push it over, another problem with working shifts if nobodies ever about through the week.

So plan B it was for now, getting burnt on my back lol



So let the cut, cut, weld weld proceed!















Cut roughly to shape


Last edited by 89Rallye; 30th May 2016 at 02:17..
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  #9  
Old 30th May 2016, 02:16
89Rallye 89Rallye is offline
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Adding some shape and strength





Trial fitting pedal assembly



This was probably the worst of the damage, and a bit tricky as its part of the body mount.



And a rather quick and messy coat of anti corrosion protection (mainly to protect it as I'm now back at work), just got one small piece to weld up then get some seam sealer and stonechip down to mask over all that dodgy welding lol



Oh and last note... PPE people!!!! not saying a glove would of stopped this but I don't think the damage would of been as bad. Not like me as we get bollock'd in work if caught without it but it only takes a split second.

Its nearly right through the tip of my finger but it could of been a lot worse.





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  #10  
Old 30th May 2016, 07:59
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Ouch!

89Rallye - Belated welcome to the forum.

Looks like you are really getting stuck into the rebuild.

Good luck, Paul.
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  #11  
Old 30th May 2016, 09:02
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Nice work, love the car, photos are great and give a great insight into the car and the task in hand.Keep posting!
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  #12  
Old 30th May 2016, 09:36
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Great work, will end up with a lovely car.

Feel your pain with the cut as I just recently done the same, although mine was on the index finger joint. 1mm cutting discs go through metal like butter so had no problem with my finger! I had leather gloves on but no guard on the grinder
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  #13  
Old 30th May 2016, 16:28
89Rallye 89Rallye is offline
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Thanks guys,

Bizarrely, there was no pain and no blood. My other half a burns specialist at a children's hospital and it never goes down well when she comes home and I'm covered in cuts and burns lol
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Old 30th May 2016, 19:27
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Quote:
Originally Posted by 89Rallye View Post
Thanks guys,

Bizarrely, there was no pain and no blood.
Same here, I think the heat from the cutting disc corterized the cut as it went, very efficient Had to go to A&E for mine though as I couldn't get the black bits of grinding disc out of the cut (again no pain when trying). Wasn't until they cleaned the cut (had to be quite aggressive) that it started to bleed.
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Old 3rd June 2016, 08:42
89Rallye 89Rallye is offline
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So with my nightshifts over I have a few days to spare, I have to say with the sun shining it made climbing underneath with a grinder and welding set rather difficult.

I am thinking of renaming it project swiss cheese though, every time I touched the floor with a wire wheel on the grinder it'd open up like a colander lol

With all the welding complete and my seam sealer lost in transit somewhere I was at a bit of a loose end so thought i'd have a look at the paint. So I took advantage of the angle while it was up on the roller and cracked out the mop.

Its been lying around god knows where for god knows how long, the paint finish didnt look too bad although there are a few dodgy areas where poor prep is present (prep marks under the paint etc) and also a few wrinkly panels although this is a fibreglass tub so a little is acceptable I guess.

There were a few marks around the body, thankfully most of them came out although theres a couple that will want a little touching up.

This was probably the worst of the damage and tbh It looked right through the paint and I did not think it would come out.



Theres still a few tiny marks but I bottled out on going any further for fear of burning right through thr paint.







Im loving the sparkle, not just a plain boring blue after all.















Just want it finished now, especially with the sun shining. i'm aiming to have it ready for its MOT by the middle of next week
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Old 3rd June 2016, 19:08
89Rallye 89Rallye is offline
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The underside is all done!!! Not the greatest photos but hopefully you'll get the picture.

Had help from my old man today too, was nice to see him with a spray gun in his hand again.






Nice coat of anti corrosion primer,



All seams and dodgy welding sealed,



Then a layer of stone chip,



Then a gloss black top coat, not the best photos but trust me its a 200% improvement.









Same treatment for the inside too, sealed, stonechipped and painted. Nothing pretty but important I think on a leaky cabriolet and hopefully it shouldnt require any more welding for a long long time!







Just have guages to rebuild, fit and rewire, few other bits of wiring to complete (fuel sender, horn). Seatbelts and seat to go in then I think she can go for an mot
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  #17  
Old 3rd June 2016, 19:47
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Well done, looking really good!
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  #18  
Old 5th June 2016, 18:15
89Rallye 89Rallye is offline
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Quote:
Originally Posted by molleur View Post
Well done, looking really good!
Thank you!

Ive had a well earned break away in the sun today, although I did call into our unit to pick up some missing bits of trim id left down there.

Yesterday didnt go so well though really,

Shes now back down on her wheels again and hopefully this is the final run in of the mot preparations. I also remembered to fill the engine with oil again before running it up! (id drained it out as I was planning on putting it on its side which never happened in the end)

Now Ive been around beetles and beetle related cars (Karmann Ghia for one) for a long time now, so I dont know if it was a hangover from the night before or the heat but it took me most of the afternoon to get the pedal assembly back in connected up and adjusted correctly.

Thankfully though after all the welding everything has lined up again.



Then things took a turn for the worse, not the end of the world admittedly but it felt like it when it happened!

I've given up on the idea of changing the gauge faces and im pretty sure a speedo is an mot requirement anyway, so I started re-assembling the puzzle.



I also installed a little upgrade ive been thinking about for the last few weeks,

LED backlighting to replace the utterly useless single bulb, not that its ever going to get much used at night but you never know.







Then fitted back into the dash along with a fuel gauge I found in a box of bits left over from my Karmann build. Which I think is better looking than the one that came out.



Ive never seen this mounting though, its a US gauge so maybe it something they use? I dont really wanting to notch the dashboard so may file these off and make a standard style mount for the rear of it.

Anyone any ideas?



Then like a dick went and dropped this while cleaning it,



You can hardly notice it though, honest!



So things are on hold again while I order up some new glass but I can complete the wiring and then I think its just seatbelts to go in and Ive a set of boots to fit to the gearbox.

Last edited by 89Rallye; 5th June 2016 at 18:24..
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  #19  
Old 22nd June 2016, 11:01
89Rallye 89Rallye is offline
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Not much to update the last few weeks, working in between shifts I've been slowly beavering away at the seemingly never ending list of jobs to do and just when you list is completed there's quickly another.

I've now got all the electrics buttoned up, have to say getting the horn to work off the steering wheel was a nightmare! The previous owner has it on a switch from the dash but I wanted it back on the new horn push. Involved a lot of head scratching but it worked out to be a worn steer bearing in the column and the column was badly adjusted/aligned when fitted (from factory). Basically the wheel kept on earthing out on the metal cowling, so it took some filing, new bearing and all was good in the end.

Everything's now working how it should expect for a big one in that it's charging. I'm putting this down to a fault Dynamo, but I do have a spare alternator which I was planning on using on another project but needs must I guess.

All gauges and warning lights now working, I don't like the fact the fuel gauge doesn't match but I can sort this at a later date. It's temperamental anyway so will need changing.



Seatbelts in, all the trim back on and there was only one thing left for it off for the mot.

Which I'm happy to say she passed with no advisories and nothing needed apart from the near side headlight was out of adjustment.

My mate dropped it off for me so no photos, I did want a nice one of the underside while it was up on the ramp lol

The piece of paper is all that matters though,





So onto hopefully the final list, I've managed to have a drive around in it now and can say only one thing and that it's terrifyingly quick and seems to bounce a lot obviously due to its light weight body, so this is something that'll need addressing. Might be able to go a touch lower at the front which might help.

I've got the interior to finish off and the wheels to polish but I'm sure there'll be more to add to that lol

Need to sort out a supplier for carpets if anyone can help?

Last edited by 89Rallye; 22nd June 2016 at 11:04..
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  #20  
Old 23rd June 2016, 20:42
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Hopefully you'll get it sorted for the one day summer we may end up having
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