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Paff
08-05-2009, 10:43
Ok guys, you know I gave up rebuilding Rusty. Well Dusty is the spitting image.

Mica blue, T-bar but 1 year younger and dramatically less rust than I was faced with.

Now this is a weird ass backwards thread that I'll have to get all the pics upladed asap but left my camera at the unit.

Basically, this is what happened.....

Sunday 26th - picked up the new car.
Next few days was dropping rusty's lump out and stripping the whole car for spares, including the modified firewall we made for Rusty.

Friday then, while I was at a party Owen started dropping the lump out of the new car.

bits and peices done over the week, including...

Cut out old firewall at the spot welds.
Weld in Rusty's firewall.
Weld in the mounts
swap fuel tank and relocate battery while at it.
swap the good bits of rusty with the not so good bits of Dusty (still got some bodywork to go tho.
adapt the clutchline bracket.
Route the pre modified loom from rusty.
put engine in and sort all the fluids

Then last night, turned the key, it started, put exhaust and wheels on and drove it round the estate.

The guy who gave me the car is shocked how quickly from picking the car up to break it to changing plans and rebuilding the V6 into it happened.

So a small bit of welding to do by the front ARB mounts, tax and insure and I'll be back on the road in a new V6.

Will get piccies up when I remember to bring the camera home

Rowdan
08-05-2009, 13:37
Nice one boyo.:thumbsup:, does it still have the Bjork exhaust?

E1uSiV3
08-05-2009, 14:07
Awesome work, im impressed how fast it has been done too!

Cant wait for pics mate.

OlberJ
08-05-2009, 19:25
Get in there Paffmeister!

Good news indeed.

Paff
08-05-2009, 19:59
Cheers guys, just sorting all the pics out off the camera and if I get time later I'll get some up.

Oh and yeah Row, it still has that oh so quiet exhaust :)

Paff
08-05-2009, 22:11
Ok quick recap of the original build with poor old rusty so people who have joined since the first build can see where it all began.

Well here goes, I'll try to include as much as possible but bear with me this is a challenge as the initial build was a couple of years ago but I have to include it as it all intergrates together for info. I'm struggling to find some of the original pics but I'll try my best.

Well from the start....

Rusty was bought as a very nice mk1 with a few minor issues, Apart from the stereo and exhaust when I bought him he was completly original.
I changed a few things and did a little detailing on the engine to end up with this.

http://www.twobrutal.co.uk/forum/images/recovered/2006/05/41.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2006/05/43.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/56.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/57.jpg

And thats how He stayed for a few years.

So Finally the Clutch went so what more of an excuse was needed to carry out an engine swap. Only thing was to decide mk1.5 or mk1.6.
Already having 1 mk1.5 close by that I could borrow and the fact there were not many V6's done the decision was made. So the initial swap began.

I painted a few parts of the engine and removed the EGR (unfortunatly I can't find any pics of the engine with the EGR installed .

I chose to go with a mk2 turbo gearbox and flywheel as I have no idea what I want to throw at the car in the future. a mk2 NA gearbox is much easier to work with as the CV joints just work and you don't need to move the supported shaft bearing along the shaft by about 4mm.
Adamh from Twobrutal modified my flywheel with the correct PCD to mount to the 3VZFE lump using ground down 4AGE Flywheel bolts..

Engine and gearbox mounted together.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/58.jpg

And stripdown of rusty commences
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/59.jpg

Then while I was at work Podge dropped the lump out of Rusty and started the mounts\firewall mdding.

Mounts removed
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/60.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/61.jpg

And the new mounts welded in, top left of the pic you can see where the firewall was cut, it was cut the same on the other side.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/62.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/63.jpg

The only pic I can find of the modified firewall.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/64.jpg
It was bent back and the sides rebuilt with new strips of metal

And so...
Mounts done, firewall done. bay prepped ready, time to get the engine in the bay to wire, plumb in and finalise everything.

engine was pushed into place under the car
http://www.twobrutal.co.uk/forum/images/recovered/2007/05/182.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/65.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2007/05/196.jpg

The only way to get it into the bay is to take the intake plenum off which is fine in itself but it does mean one of the lifting hooks is no longer attached so a strategic bolt screwed into a bolt hole somewhere on the block\one of the heads does the job (I have a new method now but we'll get to that when dusty arrives).

And finally a piccy with it in the bay.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/66.jpg

That last pic was when the headgasket went so from this point in its V6 rebuild to the state and car it is now.

More to follow, maybe later tonight if I have time and am not to pissed when I get back from the pub. From here on in its V6 rebuild, waving goodbye to rusty and welcoming dusty the new donor body :)

Oh and Ollies done me well with the insurance, so concevably next week if I get the bits of welding that are urgent done it'll be waking up all the neibours :)

Paff
09-05-2009, 10:43
Ok here we go again.

As I said, the Headgasket went so it was time to take the engine out and do a nice rebuild on it before reinstalling on it.
This meant I could change the colour on it a bit as well as all silver was too plain
.
So time to start, drop engine and get it on the stand for the second time.
http://www.twobrutal.co.uk/forum/images/recovered/2009/01/60.jpg

The top end was then stripped down and rebuild using all new gaskets.
Again I've lost pics so its a bit hard to post every part of the build.

Cams removed
http://www.twobrutal.co.uk/forum/images/recovered/2009/01/63.jpg

Manifolds removed, you can see the block looks a bit crusty, that needs a good clean
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/68.jpg

The round item next to the Oil filter\cooler some of you might recognise.

http://www.twobrutal.co.uk/forum/images/recovered/2009/01/64.jpg

Yep tis a mk1 Oil pressure sender, Adamh made me an adapter that allowed this to fit and keep the pressure guage on the dash.

Next was heads off for clean\new headgaskets\seals
http://www.twobrutal.co.uk/forum/images/recovered/2009/01/65.jpg

Headgasket mating surface wet fromthis
http://www.twobrutal.co.uk/forum/images/recovered/2009/01/66.jpg
to this
http://www.twobrutal.co.uk/forum/images/recovered/2009/01/67.jpg

And finally all painted and mostly back together
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/69.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/70.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/71.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/72.jpg

Decided to clean up the gearbox as well.
http://www.twobrutal.co.uk/forum/images/recovered/2009/01/74.jpg

We had made an adapter plate to allow the mk2 engine mount to bolt up to the block but it was a prototype so needed tidying. So we made a nice shiny one, unfortunatly I am still using the prototype as someone else had the shiny version off me for thier swap, one day I'll make one for myself :)
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/73.jpg

So we reinstalled the engine and tested it out.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/74.jpg (http://s6.photobucket.com/albums/y227/paff/Cars%20n%20bikes/?action=view&current=MOV00130.flv)
it seemed to work :D

Only the bodywork to go, so the next post is gonna be that and will signal the end of the line for Rusty as the replacement shell arrives. This is turning into a bit of a project that I doubt will ever end.

Paff
09-05-2009, 11:29
So on with the rust treatment :(


Was not looking forward to this as I know it was going to take ages.

List of things that obviously stood out and needed doing....

Rear arches, all three repair panels each side.
Front arches.
Sills
Couple of holes in floor
Rust above windscreen
Front bumper bar
Fit the Lambo style hinges

Then I got digging.....
Inner sills were shot
inner arches needed work.

The list grew and grew.

Oh and I decided I wanted a black roof.

So we got started.

I seem to have very few pics of the bodywork so I'll just have to do a small post on this one.

First job was sort the rust above the windscreenso I started with that and the black roof.
I've got pics somewhere of the holes that were in the metalwork under the windscreen but I've misplaced them, when they turn up I'll add them in.
But the roof came up quite nice considering it was a rattle can job
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/75.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/76.jpg

Next was off with the front arches this had to be done to test fit the new hinges as well.
Its always good fun removing the wings and guessing which bolts will shear you can garantee the bottom bolt into the sill will either shear or just be a rust coloured blob :)

Arch and door off ready for hinge fitting.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/77.jpg

Hinge fitted, just was being a pain to line up correctly.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/78.jpg

I know the hinges arn't to everyones taste but I like them. But I can't be bothered to fit them to the new car and deal with the hassle so I rekon they will end up on ebay :)

I had a complete rear quarter to go on the passenger side but again I can't find the pics of the old one cut off, I'll keep an eye out and if I come across them get them posted.
However starting to cut away the old arch presented me with big holes in the inner arch that needed to be repaired.
So I attempted welding knowing it doesn't need to look perfect as it was a hidden part of the car that just needed to be solid. I came up with this.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/79.jpg
It was never finished off and there was much more than that one bit on this side but it seemed to go ok.

Same done on drivers side altho I was using the repair panels not a full quarter.
Again some rebuilding of inner arch was required.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/80.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/81.jpg

The front of the arch was much worse and I hadn't really started on that before chopping the sills and seeing big flaking bits of metal that used to be the reinforcing strip.

That was as far as we got.

Chatting to Mark he mentioned he had a mk1 and his missus wanted the driveway it was on back so we travelled up with the trailer and picked it up. At the time I didn't know if it was a car for breaking or something that I'd fix\modify.
Got it back to the workshop and up on the ramp. Prodded around and altho some work is needed to bring it up to scratch its less work than was required on Rusty.

Rather upsetting, I've had Rusty for quite some time and been through loads with him but common sense (not something I have very often) made the decision for me.....

The V6 was coming out and going into the new car (lovingly named Dusty).

snowtigger
09-05-2009, 12:04
How much will the lambo door hinges be going for paffmister as quit interested as there my taste.

Paff
09-05-2009, 12:38
Here we go, the latest progress.

Dusty the new car arrives for inspection.

http://www.twobrutal.co.uk/forum/images/recovered/2009/05/82.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/83.jpg

and the 4AGE
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/84.jpg

I'm giving this away to a mate who has another shell with a blown engine and just wants to get back on the road while he builds his 4agte project.

So after the assessment and deciding it was going to be the new V6 it was time to start breaking rusty.
We dropped the V6 first, conveniently we'd made an engine trolley that fitted the V6 engine and box perfectly and to get the engine out we disconnected everything, lowered the car down until the engine was sat on the trolley and undid the side mounts.

Then I pressed the button and the car went up in the air leaving the engine sitting perfectly happy on the trolley. These things are so much easier with a 2 post lift :)

We cut everything we needed out of rusty including the firewall (wanted to transplant that as its a bit of the original build that we liked).
Then it was time to wave goodbye.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/85.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/86.jpg

From here on out its dusty's turn to shine :)

Owen did a fair bit while I was at a party, so thanks go out to him.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/87.jpg
the 4age just fell out, honestly
and then the fuel tank and coolant pipes fell out.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/88.jpg
My other fuel tank has a high flow pump in it which will be needed for the V6

So now with an empty bay and centre tunnel it was time to start the cutting and welding.
Off come the stock mounts
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/89.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/90.jpg

and out with the firewall
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/91.jpg

to be replaced with the ready modified one taken from rusty.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/92.jpg
We don't ever want to swap one of these again, it would have been easier to have modified the new wall :)

And I got to painting the bay with weld through primer in preperation.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/93.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/94.jpg

Time to test fit the firewall.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/95.jpg
scuse the ugly bugger in the bay I seemed to live in there that day :)

Firewall welded in, seam sealed and filled where it needed to be filled.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/96.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/97.jpg

Mounts held inplace for tacking in with the jig
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/98.jpg

and then welded properly and seam sealed
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/99.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/100.jpg

Also had to move the clutch line bracket out so that it would work with the mk2 gearbox
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/101.jpg

As if by magic, the bay suddenly turned blue :)
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/102.jpg

Oh I had put in Harness mounting plates as well but forgot the pics of them.

Also I removed the loom that runs down the passenger side and plugs in at the footwell to replace with the premodified loom from rusty.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/103.jpg

Anyway I have to go out now so I'll continue with the thread later. This will be an ongoing project for some time :)

Paff
09-05-2009, 12:40
If I decide to sell them I'll be asking £180 pickup only. They are heavy.

I have to warn you tho, they are universal ones and a complete twat to line up, I never managed it perfectly. You also need to modify part of the front wings, some wiring and hammer flat a couple of other bits that interfere.

Rowdan
09-05-2009, 13:50
If I decide to sell them I'll be asking £180 pickup only. They are heavy.

I have to warn you tho, they are universal ones and a complete twat to line up, I never managed it perfectly. You also need to modify part of the front wings, some wiring and hammer flat a couple of other bits that interfere.

And have arms like Garth to close them iirc.:pumped:
Some nice pics in there Paff, see a JPS detailed V6 lump even managed a cameo appearance. ;)

adamh
09-05-2009, 20:48
good show paff, hey there's a tinker trying to make off with your firewall !

Paff
10-05-2009, 00:41
cheers Row...

Wonder whos V6 that jps lump is then :)

Adam, don't worry its not a tinker tis just a short Welshman :)

Paff
10-05-2009, 10:12
So now the bay was prepped and fuel tank was in it was time to hook up the engine into its new home.

First thing was to route the modified loom where it needed to go. Surprisingly even some of the clips were unbroken so it could attach to the stock loom locations without issues :) And luckily the V6 diagnostics port fits perfectly on the tab the original one fits.

The engine was still on the trolley so we thought we'd try and lower the car down again and see if we could still get it to line up without the use of the engine crane. It worked, all that was left to have the engine in the bay was put the bolts through the mounts.

And there we go....

http://www.twobrutal.co.uk/forum/images/recovered/2009/05/105.jpg
engine in bay partly plumbed.

Time to attach the torque mounts to the chassis, reassemble the intake system, fit exhaust and build the battery tray up front.

And there we have it, engine reassembled, I don't have the plastic cover over the top, I prefer to see the "stuff" underneath :)
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/106.jpg

Oh still have driveshafts and suspention to go on as well or I don't think I'll be moving far like this :)
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/107.jpg

Fitted the tray up front to hold the battery, my welding must be getting better as it didn't fall off when I sat the battery on it :)
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/108.jpg
Ignore the little red wire spagetti behind it, I'm wiring in the engine bay fan to a switch so I can switch it on when I want unlike the last build where I didn't have a fan at all, altho it didn't seem to cause any problems.

I never had the boot lining last time so all the 3fvfe wiring was on show in the boot, decided that wasn't going to happen this time so a little bit of trimming and the front wall cover fits quite well, still needs recovering but I'm going to do the whole boot at some point.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/109.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/110.jpg

I think something was living in there at some point :) The car has been parked up outside tho and there was enough water in one of the lights to support a couple of goldfish so obviously the seals had gone there :)

So suspension next.
Now I had a set of struts on Chasey the stripped out slag that were fitted with a new set of PI springs not so long back, sorry Chasey, you going back to stock :)
So we just swapped the whole lot over.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/111.jpg
mmm springs that actually work :)
At some point the whole suspension will be overhauled but for now this'll do.

So, time to attach an the handbrake cables up and refit the undertray, its getting close when thats the jobs you can think of that are left.

Exhaust and fluids would be good too :).

I have no pics of the exhaust but I'll get the car up on the ramp later and sort that one out, its a bit loud, idles at 108ish dB's

and finally for now......
Back on the ground, lowered and sitting on its donated 17's (sorry again chasey but your not wanted any more)
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/112.jpg

And of course from the back with the freshly fitted SC lights
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/113.jpg

some welding to do today and thats it, it'll be ready to hit the road and have the other bits done as and when I get time.
Anything else I do tho I'll update on the thread so its all in one place for people.

Marksman
10-05-2009, 19:25
Not a bad effort for a week's work that :thumbsup:

Owen.

adamh
10-05-2009, 23:49
Not a bad effort for a week's work that :thumbsup:

Owen.

lucky gits know how to do it lol , mr O to hand aswell not bad someone to make the tea :thumbsup:. all i have is a cat to occasionaly sit on it outside..

Marksman
11-05-2009, 00:07
Something strange is going on, Mr Paffey is off the caffeine so tea making duties are suspended. I'm getting the hang of being a tool wallah though. Paff only has to look at a rusty bolt and I hand him the 10mm shearing tool.

That cat sounds useful, can it be trained to roll over and polish cars, and if so is it for sale?

Owen.

Paff
11-05-2009, 01:14
I use a lot of 10mm shearing tools :)

Getting the hang of welding now as well :)

Paff
11-05-2009, 01:17
Oh and Owen, I think its not the off caffine thing, its nore off the warm drinks, gonna get some beer in our fridge tho so those days when I miss last orders I can still get a drink :)

Paff
11-05-2009, 23:07
Ok for those of you that are interested. I have a rather subtle exhaust lol
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/130.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/131.jpg

Its not the final design but will do for now :)

Also I mentioned about some welding to be done, well this is the reason why....

I found a couple of holes while prodding with a screwdriver.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/132.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/133.jpg


The holes were on both sides altho the driver side was full of a bigger hole than the passenger side.

Cleaned up the underside a little.....

http://www.twobrutal.co.uk/forum/images/recovered/2009/05/134.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/135.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/136.jpg

That was after the initial clean to try and find how far I'd have to chase the rust. Broke out the wire wheel and found it was actually not much further than I'd already uncovered, so a bit more cleaning up, some welding burns in the hands, chest, back you name it, some sealing and they are a lot less holey now.

http://www.twobrutal.co.uk/forum/images/recovered/2009/05/137.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/138.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/139.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/140.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/141.jpg

And prepped ready for painting\ undersealing tomorrow.
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/142.jpg
http://www.twobrutal.co.uk/forum/images/recovered/2009/05/143.jpg

I've also sorted the insurance out on it so as of mid-day Wednesday I loose the use of the track slag and the V6 joins the party instead.

Oh and I know the welding isn't the greates but I've not really done much in the past so its a learning curve for me. Am definatly getting there tho :)

OlberJ
11-05-2009, 23:25
some welding burns in the hands, chest, back you name it, some sealing and they are a lot less holey now.


Had a welding spark land in your lug hole yet? lol

Marksman
11-05-2009, 23:35
Paff, looking better by the minute that car :thumbsup:


Had a welding spark land in your lug hole yet? lol

That's a good one isn't it? :shades:

One of the best I've seen was on a sunny pistol range. Chap using a .45 auto. Bang, then tinkle as the ejected brass bounces onto the concrete. Bang - tinkle, bang tinkle, bang - pause - nothing. Rapidly followed by shooter racking slide, removing magazine, carefully placing cleared weapon on the bench and THEN diving into open shirt collar to retrieve the red hot shell casing. rotflmao Twas impressive self control but poor choice of shooting atire!

Owen.

Paff
12-05-2009, 01:09
Yep had that, tis not a pleasant feeling

adamh
12-05-2009, 23:12
good job on the welding paff, it is the sh1ts underneath isnt it,
that darned underseal is awful stuff. nice exhaust aswell, simple is best!.
owen the cat aint for sale but i've a mind to put her indoors up for sale instead :)

Marksman
12-05-2009, 23:31
In the market for a new one of those too as it happens.

Paff
13-05-2009, 01:04
Adam, any tips to get the seam sealant off fingers, its seem to have welded itself to me :)

Hoping the insurance docs come through tomorrow then at 12 I'm going for a drive :)

Diesel Meister
14-05-2009, 18:30
Video!