Amy's Chamois Coupe

ImpManiac · Post by **ImpManiac** » Sat Dec 28, 2013 10:33 pm

Great work on the arch, Scott!

How will you tackle the pitting? Weld up the pits and pinholes?

IM

bks974c · Post by **bks974c** » Sun Dec 29, 2013 10:55 am

Paul

Any isolated pits will be welded but mostly cut out and new metal put in.

Scott

bks974c · Post by **bks974c** » Sun Mar 23, 2014 7:04 pm

Not really, welded up the rear shelf but although it looks OK think it could be better - so when I cut up the Imp for the MX Imp project I'll remove the whole shelf and weld it in.

Scott

ImpManiac · Post by **ImpManiac** » Mon Mar 24, 2014 3:49 pm

bks974c wrote:...I'll remove the whole shelf and weld it in.

Is that a difficult job, Scott? I ask because my shelf could be better. I think it can be repaired but I may be able to source another.

IM

bks974c · Post by **bks974c** » Mon Mar 24, 2014 8:42 pm

Don't know yet - I'll post up details when I do it.

Scott

bks974c · Post by **bks974c** » Tue Oct 24, 2023 10:49 pm

Well where did 10 years go

today as Karen's car nearing completion and waiting on panels for customer's Stag restoration I dug out Amy's Coupe and rolled it into the Spray Booth/workshop.

I started the restoration in a single garage at home, now have a workshop with space, a lot more tools and experience, I have also gathered most of the panels needed to do a proper job.

Started by removing all the stuff that was being store inside it, removed all the closures such as boot/bonnet/doors. Good news it looks pretty much the way it was left all those years ago

The project stalled because of the engine cover behind the rear window, I had welded it up but wasn't happy with it, so put it aside while looking for a replacement. I've waited so long that now Ex-pressed Steel manufacture them, I've got a good used one, in fact I ended up with 2 so sold one.

Having looked at the repairs again, they weren't bad in fact they would have been fine but I've already committed to doing it right, cut out old panel and currently cleaning up all the edges. Boy, does that take time

Scott

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bks974c · Post by **bks974c** » Wed Oct 25, 2023 9:12 pm

Remains of the flanges removed and replacement trial fitted.

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Scott

bks974c · Post by **bks974c** » Thu Oct 26, 2023 9:13 pm

So much work, where to start - the worst looking area without looking too hard was the passenger side front wing so started on that by removing the remains of the old wing. Inner wing gone as expected and lower hinge box fubared but bottom was solid having been repaired when we first got the car.

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Removed the underseal, that's a horrible job but can now see what we have got to play with. The H bracket while not holed is seriously weakened so that will need replacing. Have a pair of good used ones in stock

. Debating with myself whether the answer to the inner wheel arch is just to order a new one from expressed along with a half floor and maybe a battery tray. I have the club floors in stock but the Ex-pressed ones have the dip for the seat frame

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Cut out the A pillar around the lower hinge and started rebuilding it.

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Put the captive mountings back in for the front suspension, I think that might be one of the reasons the suspension still attached.

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Scott

bks974c · Post by **bks974c** » Fri Oct 27, 2023 9:33 pm

Pulled out the panels from the garage attic at home and raked around the shed for the rest.

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Put some of the panels in place so I could feel better about the amount of work ahead.

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Then continued with the repairs to the A Pillar, removed the old sill and trial fitted it to see how it meets the A pillar.

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The sill and inner sill were actually very solid but will all be replaced, I need to order an outer wheel house and battery tray from Ex-pressed but still swithering on the half floor. I want to keep the NOS wheel house for aligning panels as it as good a reference as I'll get.

I have two good saloon door that will need modifying to fit the coupe.

Scott

bks974c · Post by **bks974c** » Sun Oct 29, 2023 8:47 pm

Moved back to the passenger side mainly to check how good the repairs were or should I say accuracy, removed the window frame from the saloon door and fitted in loosely along with the front and rear wing. The door is sitting on the catch which is in it's original location and alignment really good.

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The NOS engine cover has misaligned mounting studs - possibly rejected from the production line

- filed the holes in the hinge to get it to fit, I did debate whether to cut and weld it instead. A lot of work went into the transom to wing to cover to get to a point where everything bolted up and panel gaps were good but this is the side that was hit. Happy for now but will finesse it fully at final assembly before welding.

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Scott

John A Ross · Post by **John A Ross** » Sun Oct 29, 2023 9:06 pm

Your fairliy getting through the work Scott

lovely job

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Uncle Henry · Post by **Uncle Henry** » Mon Oct 30, 2023 8:04 am

Nice progress. Great work, Scott

AG

bks974c · Post by **bks974c** » Mon Oct 30, 2023 8:12 pm

Moving forward from the back I removed the inner wheel arch, 10 years ago I made this arch as the ones that were available were worse than useless so I made my own. It did require making in several pieces and was a perfect fit but I was never that happy with it.

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10 years on and Ex-pressed Steel Panels is doing them and not a lot of money and a huge time saver. It fits very nicely to the factory panel.

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With the arch off and the edges cleaned up, it makes working in this area much easier. I decided to replace the suspension cone although it looked good it is one of the usual suspects when it comes to rust and I'd rather put the effort in now rather than find holes a few years down the road.

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However, in this case it would have been fine as solid but glad I did it anyway, Also redid a repair at the rear of the arch, originally I had overlapped it but with hindsight it would have been better butt welded so I cut it out and did that.

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Wheel housing looks great and superb fit, I did need to modify both lower ends but as both these area were previously repaired they might be the reason the mods were required.

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Rear wings fits nicely over it, another part of the jigsaw done.

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Scott

bks974c · Post by **bks974c** » Tue Oct 31, 2023 8:51 pm

Progress today was a lot slower especially after yesterdays success.

Modified the rear bin so the heater hose does not have to take 2 90 degree turns through the sill, the hose often gets crimped there and reduces the flow and the heaters are not that great in the first place. I will be putting on edging strip so the hose doesn't get cut.

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I also started thinking about fitting a valve to the bypass so that water is forced through the heater or the heater hose rather than it finding it's own way. There seems to be lots of 12v valves about fitted to modern vehicles.

Next on the list was the H bracket, unfortunately the cut sections I had that look good proved less so when they were stripped but will provide sufficient bits to make new ones.

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Scott

John A Ross · Post by **John A Ross** » Tue Oct 31, 2023 9:07 pm

Scott

I have 2 H mount cuts here that are good if you want them. They are still atatched to bits of inner wing so should come apart clean

.

bks974c · Post by **bks974c** » Tue Oct 31, 2023 10:52 pm

John A Ross wrote: ↑Tue Oct 31, 2023 9:07 pm Scott

I have 2 H mount cuts here that are good if you want them. They are still atatched to bits of inner wing so should come apart clean

.

Thanks John, I'm boxing them in anyway so happy to continue as I am.

However, if you still have some rear suspension cones I be interested in buying them.

Cheers
Scott

John A Ross · Post by **John A Ross** » Wed Nov 01, 2023 9:57 am

Scott, yes plenty here

bks974c · Post by **bks974c** » Wed Nov 01, 2023 1:41 pm

Thanks, I'll give you a shout.

Scott

bks974c · Post by **bks974c** » Wed Nov 01, 2023 9:10 pm

Continuing on with the repair to the H bracket, nice to find the arch itself in perfect condition.

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Scott

bks974c · Post by **bks974c** » Fri Nov 03, 2023 9:01 pm

Been playing with the passenger door trying to get it to fit nicely and it has been a fight. I think partially because the A pillar was extensively rebuilt so bottom hinge not quite where it should be, lesson learned when I tackle the other side.

I also removed part of the front inner arch as a couple of mm out affects the alignment hugely, have ordered an Expressed Steel repair section for this side and a full wheel housing for the other.

Starting to get it where I want it but when I began sanding my "good" door I was met with a wad of fibre fill and catty, on removal I find two scores along the door, one is pretty deep with no panel beating having taken place and one so slight it it barely noticed when running my hand over it.

I reduced much of the big dent so will only need a small skim of filler now.

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Scott

bks974c · Post by **bks974c** » Sat Nov 04, 2023 6:26 pm

H bracket time, mostly welded in. There are a couple of bits still to do but will be a lot easier when on the spit and I'm a fan of making life easier.

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Next up was tackling the bottom of the windscreen pillar, this is a common spot on Coupes but not saloons for some reason, maybe the steeper angle of the saloons means any water runs away better.

Cut out the rot and cleaned up the rust with De-Ox gel and Altrans and started rebuilding.

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Scott

bks974c · Post by **bks974c** » Sun Nov 05, 2023 8:39 pm

Working on the A pillar, the step to the scuttle panel proved problematic and took a few attempts to get right but happy with it now.

Made the first section of the scuttle repair panel, doing it in two sections so I have more room for error and adjustment.

Removed the window frame from the door and trial fitted it.

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Scott

bks974c · Post by **bks974c** » Mon Nov 06, 2023 4:44 pm

Deja Vu, H bracket time.

Inner wheel tub in good condition with only a small repair needed at the bottom by the chassis leg.

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Scott

bks974c · Post by **bks974c** » Tue Nov 07, 2023 8:07 pm

Drivers H Bracket done, usual bits to finish later.

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Shout out to Colin Rooney, sorted me out with a section to repair the inner rear arch, Top Bloke - Cheers Col

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Scott

bks974c · Post by **bks974c** » Wed Nov 08, 2023 9:08 pm

Prepping for the repair section, stripping off the underseal, except its not, well not all of it. A lot of it is Tiger seal which proved effective but a challenge to remove.

After a while I grew bored of that job and trial fitted the panel, the bottom edge of the chassis leg was quite rusty so rather than spend time trying to de-rust it, cut it out and made a new section and welded it in. I don't know why I'm back to lying on my back welding upside down

we I do it's because the Stag is on the spit

Panel in the bath being de-rusted or would have welded it in, see how it's looking tomorrow but suspect another day in there at least.

Removed more of the rear quarter, the repairs we carried out when we got the car, 20 years ago, have lasted well but coming out to do it right.

Took a rear section and split it, it has a full rear inner panel but inclined to just use a section of it.

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Scott

bks974c · Post by **bks974c** » Thu Nov 09, 2023 8:55 pm

Seems not a lot of progress for a days work but still moving forward.

Making repair sections for the rear inner quarter and put back in the acid bath to carry on de-rusting, then pulled the lower repair section and fitted that.

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Scott

oli · Post by **oli** » Sun Nov 12, 2023 7:25 pm

Good work.

I have a pair of rear 'top to bottom' corners like the Orange piece you have there if anyone else is in need. I cut them off a car because they weren't all rusted around the rear light areas like some are.

bks974c · Post by **bks974c** » Mon Nov 13, 2023 9:16 pm

Chassis leg in, outer wheel housing ready to be welded in, this side took a lot more work to get to fit properly, again at the bottom but happy to have a panel that is nearly there to start with.

More panels from Expressed Steel turned up so keep pushing on and get them fitted soon.

Today removed the rear suspension cone, it appeared in fair order but on removing there are some area where the metal is a bit thin so some plating required before new cone is fitted. Extra non factory holes found and deleted, then fought to remove old repairs and rusty panels around the crossmember mounting hopefully get some new metal back in tomorrow as long as I can get gas for the mig tomorrow.

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Scott

bks974c · Post by **bks974c** » Tue Nov 14, 2023 8:13 pm

Rebuilding crossmember area underway, I think I've made good progress during the day and then see the photos of what has been achieved and it doesn't seem much

. I'm pleased with the way it has come out so that's good.

Moved onto the suspension cone area, the spring support needed some repairs, I did look for a replacement but looks like I must have used the spares ones I had, the inner arch was a bit thin so plated it and tied it into the spring cup to spread the loads.

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Scott

bks974c · Post by **bks974c** » Wed Nov 15, 2023 10:04 pm

A day that actually looks like progress being made, finished shaping the repair section for the inner wheel arch and fitted it then welded on the outer wheel housing. Just the cone left to source and weld in.

Moved on to the front and trial fitted the outer wheel housing, the panel from Expressed Steel a good fit straight out the box

, got some repair sections to make and be fitted before it can be welded in though.

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Scott

bks974c · Post by **bks974c** » Sat Nov 18, 2023 8:02 pm

Continuing with the repairs to the inner arch, repair sections at front and rear made and fitted.

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Door fitted AGAIN to check positioning of lower hinge on the A pillar before welding.

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Inner arch welded in, and wing support reinstalled.

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Sill placed in situ, good that it still fits

, need to do some refinements to the lower wing where it meets the sill, even with factory wings I find they require work to sit nicely.

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Scott

bks974c · Post by **bks974c** » Mon Nov 20, 2023 10:50 pm

Working on getting the bottom of the wing to fit nicely, much better now but will leave final fit and welding until sill fitted.

Scuttle panel repairs ongoing, will finish when door back on.

Old sill removed.

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Scott

Dave ' Linwood ' Lane · Sat Nov 25, 2023 3:17 pm

Top work as always

bks974c · Post by **bks974c** » Tue Nov 28, 2023 10:31 pm

Been working away, inner sill on, the last of the bits on the shell removed, mainly dash and front suspension.

Shell mounted onto the spit, underseal removed, chasing the repairs that needed finishing.

Rear parcel shelf I was going to use turned out to be more pitted than I though so ordered one from Expressed Steel panels, I'm this far into it now, be daft not to do it right.

Drivers floor started, removed rear section and carried out repairs to the crossmember area,

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Scott

Dave ' Linwood ' Lane · Wed Nov 29, 2023 5:23 pm

Thats looking very expertly done

bks974c · Post by **bks974c** » Wed Nov 29, 2023 9:27 pm

Trial fitted the new half floor from Expressed Steel Panels and have to say it's a lovely fit but plenty of work to do.

I left the captive nuts in place for the moment and used them to bolt down the new floor, once happy with the way it sat pulled it out again and started on repairs to the seat subframe.

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scott

bks974c · Post by **bks974c** » Thu Nov 30, 2023 8:22 pm

This is where all the time goes during restorations, today was spent rebuilding the seat subframe and I use the word rebuilding wisely.

While it was in reasonable nick it could be better, so first off I made up the repair section for the front before cutting out the old bit and welding in the replacement.

Next up was to plate around the seat mountings as they are bad for cracking and finally made up a repair section for the rear where most of the rust was, it wasn't holed but deep enough that the best thing to do was replace.

Just to finish it off, spot welded a panel over the top, as at some stage I will have seats to source and fit and it's nice to know the floor will take whatever it needs.

Then you regret not having done the same to the other side but it wasn't an option when that was done, and another day over.

Now I bet your wondering after all that work, will it all fit back together

, well so do I but guess we will all have to wait until tomorrow.

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Scott

John A Ross · Post by **John A Ross** » Thu Nov 30, 2023 8:56 pm

Nice work Scott

I am wishing now I had added a bit of strength at the seats mounts myself. Never even thought of it.

.

impmann · Post by **impmann** » Fri Dec 01, 2023 3:08 pm

I'm loving that work under the seat pans - they aren't very strong from the factory and that looks like a very 'permanent' solution.

bks974c · Post by **bks974c** » Fri Dec 01, 2023 10:28 pm

Good news, the floor fitted back on exactly the same with all the screw holes lining up again.

Trimmed up the floor and shell for final fit and started welding it in, surprising amount of welds

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Scott

bks974c · Post by **bks974c** » Sun Dec 03, 2023 6:47 pm

With the floor partially attached time to take it off the spit and refit the panels and see how it lines up.

Not too bad as it turns out so time to spotweld the inner sill to the floor.

Needed to decide on a bonnet, the original has only one brace so decided to look for another with twin supports. All the ones I have will need work either because they have rust in the front or have been modified for front radiators. I elected to use the turquoise one simply because it was on top of the pile, it has been stone chipped on the inside so not looking forward to removing that

The bits of masking tape are notes reminding me where there is work to be done.

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Scott

The Nun · Post by **The Nun** » Mon Dec 04, 2023 2:52 pm

bks974c wrote: ↑Sun Dec 03, 2023 6:47 pm
Needed to decide on a bonnet, the original has only one brace so decided to look for another with twin supports.

Scott

Single brace bonnets were Chrysler 69 model year only, circa early H reg, and only for a short period then they changed back to a cross brace.
Rootes bonnets braces had the oval hole/slot at their forward edge.
Chrysler bonnet braces there was no hole.

.

Uncle Henry · Post by **Uncle Henry** » Mon Dec 04, 2023 5:28 pm

Single brace bonnets were Chrysler 69 model year only

And a pretty dumb thing to do, wasn't it ?

UH

bks974c · Post by **bks974c** » Mon Dec 04, 2023 8:13 pm

The Nun wrote: ↑Mon Dec 04, 2023 2:52 pm
bks974c wrote: ↑Sun Dec 03, 2023 6:47 pm
Needed to decide on a bonnet, the original has only one brace so decided to look for another with twin supports.

Scott
Single brace bonnets were Chrysler 69 model year only, circa early H reg, and only for a short period then they changed back to a cross brace.
Rootes bonnets braces had the oval hole/slot at their forward edge.
Chrysler bonnet braces there was no hole.

.

Car was registered June 68 (F reg) so maybe used a little earlier than your stating, there is no indication that the bonnet was ever changed and no signs of front end damage.

Scott

bks974c · Post by **bks974c** » Mon Dec 04, 2023 8:23 pm

After preparing the sill, edges painted with weld through primer, the rest zinc rich primer it was time to weld it on.

Made the section at the bottom of the B pillar, this bit is surprisingly awkward, it is almost corkscrew in its shape. Previous repairs by myself has seen the door fouling on these bits, hopefully tomorrow when I rehang the door, it's good to go

.

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Scott

John A Ross · Post by **John A Ross** » Mon Dec 04, 2023 8:44 pm

Is that the side pockets marked up for the new hose route Scott ?

.

bks974c · Post by **bks974c** » Mon Dec 04, 2023 9:15 pm

John A Ross wrote: ↑Mon Dec 04, 2023 8:44 pm Is that the side pockets marked up for the new hose route Scott ?

No, just an obscene drawing

Yes

Scott

bks974c · Post by **bks974c** » Mon Dec 04, 2023 9:23 pm

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The other side.

Scott

The Nun · Post by **The Nun** » Tue Dec 05, 2023 5:53 pm

It's a good idea to write comments notes sketches numbers etc on the hidden internals of your bodyshell that only you know are there, then if your cars stolen you can check if one is found whether its yours with a new identity by cutting it open to prove it

bks974c · Post by **bks974c** » Tue Dec 05, 2023 9:33 pm

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Scott