View Full Version : Phunkie little car rebuild

phunkie hiboy
28-06-13, 05:02 PM
Well, here we are on the verge of another project. This belongs to Sue, my partner, who some of you know. She's aways wanted one and the chance came about a month ago when I found this one being advertised on the RodsnSods website. It was actually being sold for a friend by the guy who did the pinstriping on the portafold. Anyway, we left Surrey at 6 this morning and wound our way down to St Austell in Cornwall to collect it.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture070_640_x_480.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture070_640_x_480.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture072_640_x_480.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture072_640_x_480.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture074_640_x_480.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture074_640_x_480.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture076_640_x_480.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture076_640_x_480.jpg.html)

english impala
28-06-13, 05:05 PM
See if that works:



And now safely back at the shop in Hook.



english impala
28-06-13, 05:06 PM
It did. The start of your photo I.D thing starts as "[img width=600 height=450]", you need to get id of the "width=600 height=450" bit so you just have [img]

phunkie hiboy
28-06-13, 05:08 PM
Sorted now, photobucket have changed everything from when I originally started this build elsewhere. Thanks anyway.

28-06-13, 05:22 PM
If that's Sue in one of the pics why does she not have overalls on and spanner in hand?:incheek:

phunkie hiboy
28-06-13, 05:43 PM
'cos she only wants to drive it once it's done!!:lol:

28-06-13, 05:46 PM
My other half has always had a yearning for a Met,
What are the plans for this one?

phunkie hiboy
28-06-13, 06:04 PM
Nothing too outrageous.

28-06-13, 07:29 PM
Nice, my wife would love one too.....

here's some inspiration from a show we were at a few weeks back.............

http://i786.photobucket.com/albums/yy149/oldfordkeith/HB%20Pictures/IMG_6330_zpsaefaef7a.jpg (http://s786.photobucket.com/user/oldfordkeith/media/HB%20Pictures/IMG_6330_zpsaefaef7a.jpg.html)

http://i786.photobucket.com/albums/yy149/oldfordkeith/HB%20Pictures/IMG_6332_zps32501627.jpg (http://s786.photobucket.com/user/oldfordkeith/media/HB%20Pictures/IMG_6332_zps32501627.jpg.html)


phunkie hiboy
28-06-13, 07:41 PM
We already got the accessory .........................

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture615_640_x_480.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/portafold/picture615_640_x_480.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture612_640_x_480.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/portafold/picture612_640_x_480.jpg.html)

phunkie hiboy
28-06-13, 07:51 PM

phunkie hiboy
28-06-13, 07:52 PM
Since Sue got the car in September, we’ve been buying parts that we know will be needed later on. Most of them have been sourced from The States, which we have sent to R&R in New Jersey, then shipped to the UK.
We have had a bit of a change of direction with the top end of the engine. Originally I was planned to use a big valve cylinder head and a pair of new Stromberg 97s, but whilst buying some other stuff, in his country, I got offered a Derrington/HRG cylinder head. This is a seven port, aluminium, cross flow head for BMC “B” series engines. There were approx 1000 of these heads made between 1958 and 1974, so reasonably rare. This one is number 78, made in July 1958, so right in the period for this car.
So in Oct/Nov I gave myself up and bought it (quite a few beer tokens). I did come with an inlet manifold though.




Once I’d got it home, I discovered what I though to be a crack in the top. If it was, I was in the s***. It was bought as seen, and I couldn’t afford for it to be a very expensive door stop!!
I had it pressure tested, and sure enough it was cracked (frost damaged probably). Now this head had been through the works about 7 years ago, new valves, valve guide, leaded valve seats, springs and fixing studs. I had never been bolted to a car since. So what to do?
Here’s the crack ……………….


This crack needed to be ground out for welding …….


Then took it to a buddy of mine to be TIG welded up ……….


It now required machining across the rocker post mounting platforms ……….


Now to make sure it wasn’t going to leak, I took it to a company in Slough (they specialise in impregnation sealing castings) … http://www.ultraseal-slough.co.uk/

So we now have a very expensive, but serviceable cylinder head rather than an expensive door stop.
I have also managed to purchase, off eBay, a pair of right in the period SU carbs to fit. Once I’ve cleaned an rebuilt these (I have the kits already) I’ll put some pictures up.

28-06-13, 08:04 PM
Cool, I love Met's. :) Strange thing though. I had a friend here yesterday and we were chatting about an old friend who worked for Derringtons and the conversation led to Derrington heads. Hadn't even thought about them for nearly 40 years and first him then your pics. Weird!

phunkie hiboy
28-06-13, 08:15 PM
Sue's first husband worked for them. Apparently Vic was a bit of a taskmaster.
When I was at college in Kingston, lunch times I'd go see what they had in their windows. All gone now, gas station there instead.

28-06-13, 08:22 PM
His name wasn't Ken was it!
I used to go there and buy their parts for my first Mini's. Trouble was that Ouvaroff was over the road and I was seduced away...

phunkie hiboy
29-06-13, 06:48 PM
His name wasn't Ken was it!
I used to go there and buy their parts for my first Mini's. Trouble was that Ouvaroff was over the road and I was seduced away...

No it was Jeff, worked in the workshop so you might not have seen him.

phunkie hiboy
29-06-13, 06:55 PM
Well, Santa visited Sue Christmas time and left her 5 of these!!


phunkie hiboy
29-06-13, 06:58 PM
Well, I’ve had a bit of time between Christmas and New Year, so I’ve managed to get a bit done .
First the crank was assembled into the block, back plate fitted and flex plate. Then the new small hitork starter, Checked out to make sure the starter engaged correctly and finally making sure I engaged and turned the crank over. All good there, so dismantled again ready to take block and crank for rebore, crank grind and full balance.
I pulled the old engine a while ago now, and the swopped in BW35 transmission.





Thought I’d start to strip other stuff out, so after a bit of a struggle managed to get the doors off.



The bonnet and the radiator slam panel.


This is the way it looked when I left for home that day .


phunkie hiboy
29-06-13, 07:03 PM
. Managed to get the doors stripped out, window glasses, door locks and handles, winder mechanisms etc. Now the drivers side door empty weighs the same as the passenger door unstripped. So what gives??
Well on closer inspection …….


It appears that there’s a bit of filler in the lower part of the door.



Now we got all the filler out in a big pile on the floor ………………


I took this home and weighed it, 3.5 lbs, in one part of the door. This what was underneath ………….


And this what the door looks like now all the crap has been removed.


We need to do the repair on the lower part of this door before the other one is started on, because we need measurements from the other door to get this one right first.

1952 Anglia
29-06-13, 08:24 PM
Looks a good project. Best of luck
Cheers Andy

phunkie hiboy
30-06-13, 07:20 PM
I though I’d try and clear the engine compartment. Started out looking like this.


And after removing radiator side supports, lower panel under radiator, air intake for heater just below the windshield.


Heater assembly.


Then disconnected wiring loom, regulator, fuse box and removed back to firewall. Removed choke cable, starter pull cable and solenoid, brake pipes and brake light switch assy. Then, removed the windshield.



phunkie hiboy
30-06-13, 07:23 PM
Still stripping bits out. Got the front wings and front panel off.





And after spending some time inside the car this is the pile of bits I ended up with.


Dash board, wiring loom, gear lever and linkage, steering box and column. So nothing inside now!!


Just about had time to remove the 3 piece rear window as well.


phunkie hiboy
30-06-13, 07:26 PM
Still pulling bits off
Fuel tank was next and it was nearly full, which I was to discover that the sender unit float was full of fuel and showing the tank to be empty. So people in the pas had been adding fuel thinking it was empty.
It’s also contaminated with water, so it’ll get used for cleaning!
Top side of the tank looks ok, but there is a leak on one point of the seam.


Underside is pretty scabby, looks like someones “repaired” a damaged part by fixing in (welded, stuck, soldered?) a square plate. Upside, it’s not leaking.


I’m thinking, when it comes to it I’ll fabricate and have TIGed up a replica in 2.5 or 3.0 aluminium.
This is pretty much the last of the stuff underneath, battery cable, brake pipes, master cylinders and brackets, steering idler, etc. The pedals are soaking in WD to get them apart. Other than that there’s only the front and rear axles/suspension to remove.


So before the car is stripped completely and the block is sent for boring, I need to check on engine/gearbox clearance issues, if there are any.
I assembled the block, front mount plate, rear plate and the transmission together. The whole idea of this is to check clearances with new engine and gearbox mounts. The transmission that the car came with is a Borg Warner 35 box. This would not have been fitted as standard, it had a 3 speed manual column change box (not he easiest thing to master), and as Sue would prefer the auto box, it’s staying.


With that done the engine/transmission was slotted back in the car and bolted in. The new head rested on and the carbs as well, as this is all a strange combination for this car. The new starter, having been modified already, was bolted in and the clearances checked all round.



Seems to be ok. Just one more thing to check is the transmission dip stick. It’s slightly too long and from the engine/trans split comes up at the wrong angle. Fitted it back on and marked where it needs to be reshaped and shortened slightly. This can be done once the unit is back out of the car.


phunkie hiboy
30-06-13, 07:30 PM
Managed to secure this little gem on US eBay out of Columbus Ohio. Paid $50 for it. $50 for an old BMC 1500 engine, halfway round the world I hear you say. You might just see that it is wearing an alloy Derrington/HRG rocker cover. Rare as hens teeth (just like the cylinder heads). Bought the whole engine, but the guy's quite happy to remove just the rocker cover and ship it to R&R in New Jersey . Judging by the price of the cylinder heads this has got to be worth a couple of hundred pounds (paid £41 inc shipping to NJ + a small amount of container space)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/KGrHqNlMFDkgy3DusBQ6biRqkpw60_57_640_x_480_zps39d7 cef4.jpg

Roland cad 500
02-07-13, 06:33 AM
Its gunna be a cool little ride.

My misses also likes them too.

phunkie hiboy
02-07-13, 08:18 PM
Yeh, we hope so Roland.

Right on with the bodywork, after hacking away at the obvious rust areas on the rear wings …………………………..



……….it was decided to remove them. These were welded on at production and as you can no longer get them new anymore, or even 2nd hand if it comes to it, it had to be done. So very carefully the seams were cut into using a real slim dremel metal disc (took ages).
The passenger side wing removed …………..



Kinda glad we did remove it now. The repairs needed to the inner arches can be carried out a lot easier, but it did show up some previous repairs that were less than ideal. These can now be corrected to a better standard.


phunkie hiboy
02-07-13, 08:21 PM
OK, so the other side rear wing needed to be removed. Now done.


The paint is now being stripped, starting with the inside, notably the floor.


This has uncovered the holes that are needing repairs. We decided not to have the whole thing media blasted (too scared).


Managed to get the transmission filler/dipstick tube sorted, with some help from Steve (BookHimDanno on here).
It was too long and not angled up enough as can be seen here


The breather was detached.


With the help of a tube bender, it was bent to a better angle. The dip stick was inserted and the projecting length measured. An amount was removed from the outer tube, internally tubed and welded. Weld was then filed, the breather cut to length, re drilled, the end sealed and the breather welded back o the outer tube. The dipstick was then inserted back into the tube and the projecting piece measured. The first measurement was subtracted from the second and the result removed from the dipstick, putting the high and low mark back exactly where it originally was. Whole thing was then trial fitted back in the gearbox.


This was the last thing that was stopping the engine being sent to the machine shop to be bored, ground and balanced .
The rear wing and inner wing situation, as regarding rust, will now be resolved. I think they are too far gone to repair with out major surgery. I have managed to get hold of some panels from a California car, which I collected from Derbyshire . They are in real good condition for their age, so watch this space.

phunkie hiboy
02-07-13, 08:25 PM
Now we have a plan, let’s put it into action. Using square tube (1”) a bracing frame is constructed (don’t know weather we need one, but belts and braces!).


Remove both the inner wings, roughly.


And finally remove the boot area covering.


Clean up the inner wing areas. These will need the parts of the inner wings, still attached, removed later.


This is what we’ve ended up with for the supply of panels, but unfortunately ::) it’s the later type with a boot lid!!


Way back in November I bought this, from a guy in Wisconsin, just in case I needed it!! :D


More to follow …………..

03-07-13, 02:46 PM
That's great work you're doing there. best of luck with the project.

phunkie hiboy
03-07-13, 09:15 PM
Thanks Stu

I realised that the exhaust manifold would have to be made so that it could be installed onto the engine, during reassembly, without having to damage any body or engine paint.
So back in the engine and trans goes and start to cut and tack weld the selection of stainless bends bought for the purpose. I had some flanges lazer cut and some stubs pressed.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture329_640_x_480_zpsce66e978.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture329_640_x_480_zpsce66e978.jpg.html)

Using a spare big valve iron head as a jig.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture335_640_x_480_zpsf288d197.jpg[/img] (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture335_640_x_480_zpsf288d197.jpg.htmlhttp://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture339_640_x_480_zps9c6d69e5.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture339_640_x_480_zps9c6d69e5.jpg.html)

The routing of the primary pipes is so tight that they have to go down, one over the other and not side by side.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture337_640_x_480_zps6687984e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture337_640_x_480_zps6687984e.jpg.html)

Now to remove the engine/trans (this will not go back into the car until all the body and paint has been done and the engine reassembled) and finish the manifold collector and first bit of the front pipe.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture343_640_x_480_zps73667a0e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture343_640_x_480_zps73667a0e.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture350_640_x_480_zpsb2bcfa47.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture350_640_x_480_zpsb2bcfa47.jpg.html)

Now the pipes/bends are all tacked and the tacks cleaned up, I’m going to take all this lot to be TIGed up by a buddy of mine after which all the welds will be cleaned up before final assembly and polishing.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture351_640_x_480_zps72287efa.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture351_640_x_480_zps72287efa.jpg.html)

Getting replica body sills have been a bit of a task. To my good fortune, a guy in the Met owners club (Pete Whetstone) had a pair of brand new (as near as you’ll get to the originals) sill. These were not for sale but he kindly lent one side to me to get some folded up.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture331_640_x_480_zpsef563d38.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture331_640_x_480_zpsef563d38.jpg.html)

So I approached Fintan at F H Ellis ( http://www.fhellis.com/ ) to see if he could help me out. Two weeks later I came away with these basic folded pieces of metal.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture3301_640_x_480_zps25b94ff6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture3301_640_x_480_zps25b94ff6.jpg.html)

phunkie hiboy
03-07-13, 09:25 PM
Now to start to cut and add the extra pieces required to fit.
Inner sill

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture332_640_x_480_zpse0f50e6e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture332_640_x_480_zpse0f50e6e.jpg.html)

Outer sill.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture334_640_x_480_zps3d892144.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture334_640_x_480_zps3d892144.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture333_640_x_480_zpsd2e82d86.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture333_640_x_480_zpsd2e82d86.jpg.html)

The original sill had to go back (met Pete at Enfield, he lives in Nuneaton) so I just tacked up one sill and now have a part finalised jig to do the job properly.
Something else I needed to do is sort the boot floor. The original has peppered holes all over it. The new rear end has a solid floor. Had to be careful not to damage any other panel that I need to use, but I’ve managed to remove it in a fairly good condition, just need to do some small repairs and a depaint and rust before fitting it.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture341_640_x_480_zps6acbdee6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture341_640_x_480_zps6acbdee6.jpg.html)

More to follow ………………….

03-07-13, 09:44 PM
Not sure how far you have gone with the fuel tank yet, but the one on the Pontiac was like a sieve when I cleaned it up.
I used a product called Tank Re-Nu, applied by Arrow Radiators (http://www.arrowrad.co.uk/fuel-tanks.html)in Melksham.

They line the tank inside and out, and provide a limited lifetime guarantee. It looks like a resin bonding, was completed quickly, and as it utilised the original tank you get a perfect fit. A replacement tank wasn't an option on my car.

It wasn't cheap, but might be less than having a tank fabricated. Its worth a call to them, and I have really pleased with mine.


phunkie hiboy
03-07-13, 10:03 PM
Thanks for that, Dan. Looks like it could be an option.

03-07-13, 10:05 PM
Cool project.

phunkie hiboy
04-07-13, 09:10 PM
Thanks Mark.

So, still removing stuff, but seeing the light at the end of the tunnel for the rear end now.
Cut out roughly the boot floor. This is it next to the replacement going in.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture352_640_x_480_zps23915776.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture352_640_x_480_zps23915776.jpg.html)

Then clean up the main “chassis” members ready for the replacement floor.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture353_640_x_480_zpsca72a914.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture353_640_x_480_zpsca72a914.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture355_640_x_480_zpscb3c88da.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture355_640_x_480_zpscb3c88da.jpg.html)

There are a couple of small repairs to carry out on the ends, and doing them now will make the whole job easier.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture356_640_x_480_zps8b3c9899.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture356_640_x_480_zps8b3c9899.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture357_640_x_480_zpsa40de8f7.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture357_640_x_480_zpsa40de8f7.jpg.html)

04-07-13, 09:28 PM
blimey chris you must have some time on your hands:lol:

phunkie hiboy
04-07-13, 10:46 PM
Not as much as you might think!! So far, up to now, this has taken about 7 months

phunkie hiboy
11-07-13, 10:27 PM
Now, the chassis end pieces have been replaced with good metal and the rear ½ cross member spot welded back on.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture362_640_x_480_zps7dea4b94.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture362_640_x_480_zps7dea4b94.jpg.html)

As this car may well tow our Portafold caravan, I decided to add some strength to the rear. So made an internal cross member, out of 2mm wall 2” x 1” box. To that welded some turned spacers and side link pieces.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture363_640_x_480_zps9e4f1a2b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture363_640_x_480_zps9e4f1a2b.jpg.html)

Now the ready to fit boot floor, with a coat of epoxy primer.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture365_640_x_480_zps06649d74.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture365_640_x_480_zps06649d74.jpg.html)

And spot welded into position.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture366_640_x_480_zps349fde9b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture366_640_x_480_zps349fde9b.jpg.html)

And now the battery box support sides and the rear spring hanger support plate. All the inside of box sections have been painted with red oxide.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture369_640_x_480_zpsfa29a38c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture369_640_x_480_zpsfa29a38c.jpg.html)

The exhaust manifold has been welded up, sanded off and polished.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture377_640_x_480_zps3df9c37b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture377_640_x_480_zps3df9c37b.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture376_640_x_480_zpseee95d5f.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture376_640_x_480_zpseee95d5f.jpg.html)

That’s all finished now, until final assembly.
The rear end bodywork has now been cleaned of all its surplus seams and has gone of to the media blasters, should have it back next Thursday.

12-07-13, 06:24 AM
Great build Chris.:)

12-07-13, 05:23 PM
yea great,great patience,it would have got the hiab thru it now if that was me, i all for building a rod /car, but fuck that, well done chris

phunkie hiboy
12-07-13, 05:49 PM
Fanks guys

And what's that say in your signature, Stretch !! :pmsl:

12-07-13, 05:53 PM
When you do stuff, you do it RIGHT.:wave:

phunkie hiboy
12-07-13, 07:38 PM
I had a good mentor, Gerry

12-07-13, 07:42 PM
yea i built me chevy,but it was rust free apart from a pair of new wings,it was more of a strip down and rebuild /replace parts,than a renovation, i do like a neat bit of engeniering
not meaning to hijack your thread chris

english impala
12-07-13, 08:01 PM
Some excellent work going off here!!!!!

phunkie hiboy
13-07-13, 08:09 PM
Thank you.

Didn’t want to do anything too taxing or strenuous today (31 degrees in the end), so I decided to make an engine. This would move the project on and also get rid of the growing mountain of cardboard boxes that housed various parts.
So, start with a block that’s been checked and bored.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture379_640_x_480_zpsf4fa6025.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture379_640_x_480_zpsf4fa6025.jpg.html)

And a crank that’s been ground, polished and balanced.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture380_640_x_480_zps5c04788d.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture380_640_x_480_zps5c04788d.jpg.html)

Put them together, then add some pistons and rods.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture382_640_x_480_zps0a7bb101.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture382_640_x_480_zps0a7bb101.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture385_640_x_480_zps601254b8.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture385_640_x_480_zps601254b8.jpg.html)

Add a Piper “automatic grind” camshaft.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture386_640_x_480_zpsd46a5340.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture386_640_x_480_zpsd46a5340.jpg.html)

Bolt on a new timing chain set and tensioner.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture387_640_x_480_zps8b92eea0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture387_640_x_480_zps8b92eea0.jpg.html)

Fit an oil pump and the sump, and finally cover it all in BMC green.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture390_640_x_480_zpsf4ab75e1.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture390_640_x_480_zpsf4ab75e1.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture389_640_x_480_zpsdfe5292a.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture389_640_x_480_zpsdfe5292a.jpg.html)

‘Nother little job done!!

13-07-13, 08:20 PM

phunkie hiboy
15-07-13, 06:24 AM
Thanks Daz

farncombe pop
15-07-13, 07:21 AM
Fantastic work :tup:

Hot Rod Widow
15-07-13, 07:46 AM

phunkie hiboy
16-07-13, 08:47 PM
Just thought I’d do a bit more at lunch time. Had already got in early and put a last coat of engine paint on. On Saturday the paint was going off almost as soon as it was leaving the bristles on the brush!!
Fitted a few little bits and pieces, engine mounts, block drain tap, oil pipe to the filter, fuel pump and engine breather pipe. Fitted the distributor and timed it up using the points that were in it.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture391_640_x_480_zps1365a1e3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture391_640_x_480_zps1365a1e3.jpg.html)

Then took the points and condensor out and fitted a Pertronix kit instead.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture392_640_x_480_zps452a6cb2.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture392_640_x_480_zps452a6cb2.jpg.html)

I needed to finish off making and fitting the plug leads, so fitted the dynamo and distributor cap to get the leads the right length.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture394_640_x_480_zps6d084d90.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture394_640_x_480_zps6d084d90.jpg.html)

Whilst I was at it, I thought I’d try the exhaust manifold to see what it looked like against the new paint.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture393_640_x_480_zps760f67bc.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture393_640_x_480_zps760f67bc.jpg.html)

The head is only fitted with a couple of studs, the motor will be installed with the gearbox but without the head when the time comes. So now the engine is wrapped up and sealed until we need to install it.
The rear end bodywork comes back from the media blasters on Thursday, so I can get on with the metalwork then.

18-07-13, 05:12 PM
i saw the rear end being dragged over the 331 at about 3.30 today chris, so i guess the blasters have finished with it,who do you get to do your blasting?

phunkie hiboy
18-07-13, 06:48 PM
Yeh, got it back to the shop quick before it started to rain!! I use Elgamec, don't know any where else locally.

You may remember this scabby old bit of rear end body work

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture309_640_x_480_zps0f3ddffc.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture309_640_x_480_zps0f3ddffc.jpg.html)

Well it came back from the blasters today, and this is what it looks like now.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture395_640_x_480_zpsc8b14480.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture395_640_x_480_zpsc8b14480.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture396_640_x_480_zpsc91466e1.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture396_640_x_480_zpsc91466e1.jpg.html)

I’ll put a coat of epoxy primer over it tomorrow.

JB Chevy
19-07-13, 01:59 PM
F*ck that is a project and a half you've taken on and a blinding job you are doing....... :tup:

phunkie hiboy
23-07-13, 07:34 PM
Thanks John.

OK, so just a small update.
Managed to get a coat of epoxy primer on the rear end bodywork before the rains came.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture399_640_x_480_zps2ed47a60.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture399_640_x_480_zps2ed47a60.jpg.html)

Stripped the rear end down for the parts to go to various places. The casing, brake back plates, U bolts, spring front mounts to the powder coaters. The 3rd member to the axle specialists, Hardy Engineering http://www.hardyengineering.co.uk
And the springs to Brost Forge for re arching.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture398_640_x_480_zps14f90d2b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture398_640_x_480_zps14f90d2b.jpg.html)

Thought I’d have another look at the body work. The bottom of the passenger “B” post is a real mess.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture397_640_x_480_zps6629dc8c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture397_640_x_480_zps6629dc8c.jpg.html)

Think we’ll start by putting some more bracing in and get the sills sorted before putting the rear end bodywork on finally.

23-07-13, 10:08 PM
Eeww! rust :confused: you aint scared of chopping it up that's for sure!

phunkie hiboy
23-07-13, 10:37 PM
You think!! its got to get worse before it gets better :eek:

24-07-13, 09:36 PM
Enjoying this build, that exhaust is a work of art, won't be much left of the original body a true labour of love.


phunkie hiboy
24-07-13, 09:55 PM
won't be much left of the original body


It's either do it this way or, basicly throw it away. We have done a lot of research and it seems that this car could be the earliest right hand drive UK car surviving. It was built in the first full week of production of home market cars, so throwing it away is not really an option.

phunkie hiboy
28-07-13, 12:15 PM
Managed a bit more, yesterday. Added some more bracing.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture400_640_x_480_zpsdf578303.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture400_640_x_480_zpsdf578303.jpg.html)

Then started to remove the passengers side sill, Quite a mess in there.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture401_640_x_480_zpsfc12b719.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture401_640_x_480_zpsfc12b719.jpg.html)

Stripped the whole length of the sill out and did a trail fit of the new inner sill. Looks to be a good fit, just got to clean out inside the chassis an treat it before the whole sill can be fitted.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture402_640_x_480_zpscd6c5bc6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture402_640_x_480_zpscd6c5bc6.jpg.html)

24-08-13, 06:51 AM
You doing good with that Chris ,Saw thses at a shownear hear did not know if you had a metropolitan you had to have a portafold




phunkie hiboy
24-08-13, 07:40 AM
Not done much lately, Mike, loads of other stuff to do. I'll be back on it today. Yes, it's the rules, if you've got a Met you have to have a Portafold!! That must have been Tatton Park, we did the week before at White Waltham, the Retro Festival and the national Portafold annual gathering, (33 Portafolds) and there were a couple of Mets there. Update later, on todays work.

phunkie hiboy
24-08-13, 07:28 PM
I’ve been try to get round to fitting the car on the rotisserie, that was fabricated for it (as I couldn’t find one to buy) for quite a while.
So at last today it’s now fitted, which will now make it a lot easier to do the repairs on the underside and inside the side chassis members.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture403_640_x_480_zps65762d5c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture403_640_x_480_zps65762d5c.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture404_640_x_480_zps074360e3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture404_640_x_480_zps074360e3.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture405_640_x_480_zpsabb705d4.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture405_640_x_480_zpsabb705d4.jpg.html)

As I say, it’ll be easier to get to these sort of bits now.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture407_640_x_480_zpse6a3c02e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture407_640_x_480_zpse6a3c02e.jpg.html)

Hemi Bucket
15-09-13, 09:43 PM
Bloomin' flip, you're not messing around are you?! I love reading your build threads, keep up the excellent work.

phunkie hiboy
16-09-13, 09:23 PM
Thanks Al, bit more of an up date for you.

So this is the really boring bit, Loads of work and things move forward very slowly.
Now we’re able to turn the car upside down it is a lot easier to do the under car repairs.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture408_640_x_480_zpscfe00063.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture408_640_x_480_zpscfe00063.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture409_640_x_480_zps4b6e98ee.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture409_640_x_480_zps4b6e98ee.jpg.html)

Took a while but they now look like this ………………….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture413_640_x_480_zps91a32720.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture413_640_x_480_zps91a32720.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture412_640_x_480_zpsfe55052b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture412_640_x_480_zpsfe55052b.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture415_640_x_480_zpsbdeccdc6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture415_640_x_480_zpsbdeccdc6.jpg.html)

Finished all the major work on one side inner and outer sill

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture410_640_x_480_zps19c7ffb4.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture410_640_x_480_zps19c7ffb4.jpg.html)

Joined the two together with four tack welds.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture411_640_x_480_zpsd102255e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture411_640_x_480_zpsd102255e.jpg.html)

Then a trial fit, all is good.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture414_640_x_480_zpsd656cdde.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture414_640_x_480_zpsd656cdde.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture416_640_x_480_zps5ce51d19.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture416_640_x_480_zps5ce51d19.jpg.html)

So I now have to put the large holes in the inner sill and spot weld the inner and outer together, but more of that later.

17-09-13, 05:18 PM
Coming along nicely. I have always liked Metropolitans. I saw one many (many) years ago as a boy and loved the door tops. Green and white as I recall.

phunkie hiboy
17-09-13, 06:03 PM
Thanks Dusty, the reason Sue wanted one of these, was the door tops.

phunkie hiboy
22-09-13, 09:46 AM
It’s kind of cool to actually start fitting bits back on after so long removing parts.
So now with the passenger side inner and outer sills fabricated, holes cut and flared in the inner sills, rust treated and red oxide primed inside ……..

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture417_640_x_480_zpsc687ec96.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture417_640_x_480_zpsc687ec96.jpg.html)

They are fitted together and spot welded …….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture418_640_x_480_zpsb12c389a.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture418_640_x_480_zpsb12c389a.jpg.html)

Then assembled to the car and welded …….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture423_640_x_480_zpsc2e59684.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture423_640_x_480_zpsc2e59684.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture421_640_x_480_zps88fefec6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture421_640_x_480_zps88fefec6.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture420_640_x_480_zps278d3d13.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture420_640_x_480_zps278d3d13.jpg.html)

Once the sills were attached the lower portion of the “A” post renewed, replacing the old rusted out portion ………

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture419_640_x_480_zpsd6f440e8.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture419_640_x_480_zpsd6f440e8.jpg.html)

The rear most part of the sill and the lower portion of the “B” post repair will be addressed when the rear end body work is fitted on.
With one side sill now done we need to start stripping the drivers side out.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture422_640_x_480_zps561e03c7.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture422_640_x_480_zps561e03c7.jpg.html)

There was only one jacking point on this car (passenger side). Looks pretty scabby, so we’ll remove it …..

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture425_640_x_480_zps98ce03c3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture425_640_x_480_zps98ce03c3.jpg.html)

And replace with new later model jacking points …..

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture424_640_x_480_zps48590d07.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture424_640_x_480_zps48590d07.jpg.html)

Getting further into removing the sill, it’s become evident that it’s been done a couple of times before!!

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture427_640_x_480_zps1133362f.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture427_640_x_480_zps1133362f.jpg.html)

phunkie hiboy
22-09-13, 09:48 AM
one more picture 'cos it'll only let me load 10 pictures at a time.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture426_640_x_480_zpsdfaf2d94.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture426_640_x_480_zpsdfaf2d94.jpg.html)

Hopefully get some more done this week.

Captain Scarlet
23-09-13, 08:55 AM
Fantastic build work Chris
You are to be congratulated for rescuing this car correctly :tup:

And i have never seen a car/caravan combination that looks so cool.

JB Chevy
24-09-13, 03:56 PM
PMSL about the door tops........ I think you could have saved yourself a lot of work by just cutting the door tops for you wife then, as they are probably the only bit you won't have to make :incheek:

You are doing an absolute cracking job of this car, I would not have done it there is soooo much structural rust but you are basically fabricating the whole car stunning work.


JB Chevy
24-09-13, 03:57 PM
one more picture 'cos it'll only let me load 10 pictures at a time.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture426_640_x_480_zpsdfaf2d94.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture426_640_x_480_zpsdfaf2d94.jpg.html)

Hopefully get some more done this week.

Carnage................... :tup:


phunkie hiboy
25-09-13, 05:17 PM
Fantastic build work Chris
You are to be congratulated for rescuing this car correctly :tup:

And i have never seen a car/caravan combination that looks so cool.

Thanks Ian, we hope the combination works ok. We're just using a different twist in colour scheme, instead of matching the Portafold to the Met, we're matching the Met to the Portafold !!

phunkie hiboy
25-09-13, 05:24 PM
PMSL about the door tops........ I think you could have saved yourself a lot of work by just cutting the door tops for you wife then, as they are probably the only bit you won't have to make :incheek:

You are doing an absolute cracking job of this car, I would not have done it there is soooo much structural rust but you are basically fabricating the whole car stunning work.


As far as the door tops are concerned, you're quite right, John.
And far as the fabrication of the whole car, we're so far in, we don't have a choice and if you look at post #59, that might explain why as well.

25-09-13, 07:44 PM
Chris you are an extremely brave man!

phunkie hiboy
25-09-13, 08:05 PM
Chris you are an extremely brave man!

Either that, or extremely stupid!! Like I say too far in to stop now.

25-09-13, 08:14 PM
Either that, or extremely stupid!!

Nawww just a really cool guy who know what he wants... Respect dude, respect.:woohoo:

phunkie hiboy
07-10-13, 07:25 PM
Thanks for that Gerry

The chassis parts on the drivers side seem worse than the passenger side, for some reason.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture428_640_x_480_zps56458958.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture428_640_x_480_zps56458958.jpg.html)

So this will need to be replaced together with the front floor box section, which has an access hole to install the hand brake cable and clevis. All I had to go on, as far as the hole was concerned was these two broken bits of metal (on the right) and the bit left from the passengers side.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture434_640_x_480_zps2d203e93.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture434_640_x_480_zps2d203e93.jpg.html)

So putting the whole lot together I managed to get the right size and shape hole with a return on the inside edge.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture431_640_x_480_zps7481634c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture431_640_x_480_zps7481634c.jpg.html)

Assembled with the new “chassis” piece and the gearbox cross member it looks like this.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture429_640_x_480_zps94f61b86.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture429_640_x_480_zps94f61b86.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture430_640_x_480_zpsce374053.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture430_640_x_480_zpsce374053.jpg.html)

With all that fully welded, the other sill was required. So as not to bore you all, the sill was fabricated and constructed in the same way as the passenger side and welded on. Reconstruction of the lower portion of the drivers side “A” post was needed, and followed the same route as the other side.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture441_640_x_480_zpsd20c8e6c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture441_640_x_480_zpsd20c8e6c.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture444_640_x_480_zps8d37a019.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture444_640_x_480_zps8d37a019.jpg.html)

Now with a coat of rust inhibitor, it’s ready for some epoxy primer. I’ll get round to that in the next few days.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture445_640_x_480_zpsa238fd62.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture445_640_x_480_zpsa238fd62.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture446_640_x_480_zps2d938d37.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture446_640_x_480_zps2d938d37.jpg.html)

I have now cut away most of the “B” posts, except for the main door jamb plate (the later ones, as on the new rear end, are a different shape, as are the rear of the doors), we’ll use those to fit to the new rear end bodywork.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture437_640_x_480_zps0a2c970d.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture437_640_x_480_zps0a2c970d.jpg.html)

phunkie hiboy
07-10-13, 07:26 PM
http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture438_640_x_480_zpse801c342.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture438_640_x_480_zpse801c342.jpg.html)

The roof returns at the rear need restoring ……

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture440_640_x_480_zps9fb6ca28.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture440_640_x_480_zps9fb6ca28.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture439_640_x_480_zpsfefcaaf6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture439_640_x_480_zpsfefcaaf6.jpg.html)

So all cleaned up and fabricated pieces welded in ….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture443_640_x_480_zps71cda7fe.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture443_640_x_480_zps71cda7fe.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture442_640_x_480_zps2c6ce6fd.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture442_640_x_480_zps2c6ce6fd.jpg.html)

That’s it for the moment, the next job will be to attach the rear end bodywork, but this needs some remedial work before the two can be joined together. That’ll be for the next update.

08-10-13, 08:53 PM
u wanna get u finger out chris wheelsday aint far away:incheek:

phunkie hiboy
08-10-13, 09:59 PM
Didn't say which wheels day though, did I?

09-10-13, 05:18 AM
bloody hell chris.. what a rot box! but your doing a great job on it, gonna look ace!

phunkie hiboy
09-10-13, 06:25 AM
Yeh, I know. We didn't realise it was quite as bad as it is, when we bought it.

09-10-13, 06:47 PM
Yeh, I know. We didn't realise it was quite as bad as it is, when we bought it. who did you go with to look at it chris, ray fuckin charles?:incheek:

phunkie hiboy
09-10-13, 08:04 PM
Bought on the strength of two photos :pmsl:

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/248500fde96454ea_640_x_480_zps41c10654.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/248500fde96454ea_640_x_480_zps41c10654.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/248500fde96d5b1d_640_x_480_zpsf4cbd6db.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/248500fde96d5b1d_640_x_480_zpsf4cbd6db.jpg.html)

phunkie hiboy
12-10-13, 07:47 PM
Right, onto the rear end bodywork. Even though this came from California, it doesn’t mean that’s it is totally rust free!!
Sometime in it’s previous life, the car it belonged to got rearended. It had not been repaired very well, where another rear panel had been fitted the inner wheel arches had been lapped over each other and welded on the inside only, meaning water got under the joint and rusted them out. The bad parts were cut out and new sections added.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture447_640_x_480_zps0955af51.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture447_640_x_480_zps0955af51.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture448_640_x_480_zps256029f6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture448_640_x_480_zps256029f6.jpg.html)

New corner fillets were fabricated and welded in, enabling the lower outer wing pieces to be secured properly. I had to replace an area around the left hand rear spring hanger at the same time.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture449_640_x_480_zps341ca5a5.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture449_640_x_480_zps341ca5a5.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture450_640_x_480_zps090c84b0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture450_640_x_480_zps090c84b0.jpg.html)

The areas behind the inner wings were then sealed, usually this gap is filled using old fashioned dum dum, but I’ve used Sikoflex.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture451_640_x_480_zpse418ec5e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture451_640_x_480_zpse418ec5e.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture452_640_x_480_zpsa21e9fd3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture452_640_x_480_zpsa21e9fd3.jpg.html)

Now the rear part of the assembly is ready to go, the front part needs attention. The “B” post front skin is different from the early to the late model cars. So I need to use the two that are on the car and join the rest of the rear assy to them. I cut off the front panel, had to do this in pieces to save the structure behind.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture457_640_x_480_zps85a4639c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture457_640_x_480_zps85a4639c.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture458_640_x_480_zpse060ed4b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture458_640_x_480_zpse060ed4b.jpg.html)

Then remove the old inner sill, this was pretty mangled so I will have to make up some small repair pieces when it comes to fit this to the car.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture460_640_x_480_zps08590144.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture460_640_x_480_zps08590144.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture461_640_x_480_zpsaac16bc8.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture461_640_x_480_zpsaac16bc8.jpg.html)

phunkie hiboy
12-10-13, 07:47 PM
http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture462_640_x_480_zps219403cf.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture462_640_x_480_zps219403cf.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture463_640_x_480_zps8b1396a5.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture463_640_x_480_zps8b1396a5.jpg.html)

That’ll do on this side for the time being, now onto the other side which is in a worse state.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture464_640_x_480_zpsb78dd3e5.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture464_640_x_480_zpsb78dd3e5.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture455_640_x_480_zpsf623748b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture455_640_x_480_zpsf623748b.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture456_640_x_480_zps4c40228e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture456_640_x_480_zps4c40228e.jpg.html)

That’s as far as I got today, some more next week maybe.

12-10-13, 09:05 PM
jeez that's a hell of a lot of work you`ve done there chris

phunkie hiboy
17-10-13, 08:57 PM
Tell me about it, Daz

I’ve been able to spend some time this week, here and there. I chose to do something that required removing the last mechanical items from the car.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture465_640_x_480_zpsb84aecca.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture465_640_x_480_zpsb84aecca.jpg.html)

After removal ………….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture466_640_x_480_zps5b0c37d2.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture466_640_x_480_zps5b0c37d2.jpg.html)

This is the set up that is being used to replace the drum brakes, a late MG Midget front disc brakes. I’ve seen quite a few of these conversions done in the States, but not here.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture467_640_x_480_zps7ae2292f.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture467_640_x_480_zps7ae2292f.jpg.html)

With the old suspension removed the next job is to fit a front anti roll bar. These little cars didn’t come with one as standard and with the soft suspension, they suffered with a bit of body roll. With a bit of research, I reckon an up rated 1500cc MG Midget bar will do the job. Their weights are pretty similar. As an aside, most of the suspension and steering used ‘50s period BMC/Austin set up together with a BMC “B” series engine.
The new “state of the art” Midget lower suspension arms were fitted, with new bushes and assembled onto the car. Drop links and brackets fitted to the lower arms and the anti roll bar fitted to the drop links.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture468_640_x_480_zps49ea1abc.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture468_640_x_480_zps49ea1abc.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture469_640_x_480_zpsa5d29545.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture469_640_x_480_zpsa5d29545.jpg.html)

A pair of brackets were fabricated to attach to the front engine mount cross member and the ARB securing brackets. With a bit more fettling these will be ready for powder coating.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture470_640_x_480_zps30901723.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture470_640_x_480_zps30901723.jpg.html)

And here we have the finished article ………..

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture471_640_x_480_zps8b128048.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture471_640_x_480_zps8b128048.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture472_640_x_480_zps4ed69d5c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture472_640_x_480_zps4ed69d5c.jpg.html)

Now back to the bodywork. I’m going to attempt to fit the rear end body work at the weekend, so maybe another update then!!

18-10-13, 05:41 AM
There are no words Chris!

phunkie hiboy
18-10-13, 05:39 PM
I got plenty Steve, they get used now and again!! :D

18-10-13, 05:53 PM
We had an early merc 230 in recently, owned by a Swiss guy. total ground up resto (seen the pictures) and i think you are putting more into this metro than they did. Value of the Merc now 80K.
Makes you wonder, doesn't it.

Cant wait to see it finished. Nats next year?????

phunkie hiboy
18-10-13, 07:30 PM
Don't think a met will ever be worth 80k!!

Like to think it'll be ready for then, maybe before?

18-10-13, 07:39 PM
Don't think a met will ever be worth 80k!!

yeh but the work put in to it, IS

steve 5-6-7 & 62
18-10-13, 07:43 PM
Really enjoy your builds Chris, thanks for taking the time to do them !!

phunkie hiboy
18-10-13, 07:45 PM
You're welcome Steve.

phunkie hiboy
19-10-13, 07:49 PM
Well, I feel that I’ve actually achieved something today. After all the niggly little repairs to the sills, underside and the new rearend bodywork, we now have rear wings and rear panel on the car!!
This is the rear assembly ready to go ……………..

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture473_640_x_480_zpsaa4673f6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture473_640_x_480_zpsaa4673f6.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture474_640_x_480_zps342c1a3d.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture474_640_x_480_zps342c1a3d.jpg.html)

And the car, with the “B” post front panels cut down, all ready to receive the rear end bodywork …………..

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture475_640_x_480_zpsd9fb907f.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture475_640_x_480_zpsd9fb907f.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture476_640_x_480_zps2e3a234f.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture476_640_x_480_zps2e3a234f.jpg.html)

So still on the frame at the front and with the back floor chocked up and the rear frame removed, the bodywork was introduced using an engine crane ………….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture478_640_x_480_zps58aae855.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture478_640_x_480_zps58aae855.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture479_640_x_480_zpsb4c4c375.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture479_640_x_480_zpsb4c4c375.jpg.html)

Pulled and heaved and levered (and used some of those words, Steve) the bodywork onto the car. Welded the joints on the outside of the “B” posts and as I couldn’t get the spot welder to the inner seams, I drilled and rosette welded them.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture481_640_x_480_zps7c6b38d9.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture481_640_x_480_zps7c6b38d9.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture482_640_x_480_zps661ea3a0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture482_640_x_480_zps661ea3a0.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture480_640_x_480_zps76fcded9.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture480_640_x_480_zps76fcded9.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture485_640_x_480_zps5da7a186.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture485_640_x_480_zps5da7a186.jpg.html)

phunkie hiboy
19-10-13, 07:49 PM
The rear seam, boot floor to rear panel, was then spot welded. After making a tool to pull the shock towers down to the boot floor, the originals were spot welded, Ive started to rosette weld through the drilled out spot welds and to weld all round the seam to the floor.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture483_640_x_480_zps27bcb104.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture483_640_x_480_zps27bcb104.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture484_640_x_480_zps83f6c4a3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture484_640_x_480_zps83f6c4a3.jpg.html)

Sorry about the last picture, bit fuzzy, I’m off for a couple of beers now and watch some nitro racing!!

19-10-13, 08:15 PM

Hemi Bucket
23-10-13, 11:35 PM
I don't often swear [!], but fucking hell Chris! That is all.

24-10-13, 02:44 AM
Great work there chris..:tup:

24-10-13, 08:50 AM
Great progress, even the box section frame is a work of art.


phunkie hiboy
24-10-13, 06:48 PM
Daz, thank you

Al, I swore a lot trying to get that bodywork on :grr:

Liam, thanks

Ian, just as well you can't see it up close, it'll be out soon

phunkie hiboy
26-10-13, 09:36 PM
Now with the rear bodywork fully welded on

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture489_640_x_480_zpsb24e1ae1.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture489_640_x_480_zpsb24e1ae1.jpg.html)

And the “B” posts fully welded top, to the roof, and bottom, to the sill

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture488_640_x_480_zps68149f53.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture488_640_x_480_zps68149f53.jpg.html)

The fillets that hold the roof to the body can be refixed

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture487_640_x_480_zps8c322288.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture487_640_x_480_zps8c322288.jpg.html)

And also the lower parts of the inner “B” posts. I had to remove these as I couldn’t fit the rear on due to the shape of the inner sill, that they fix to

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture486_640_x_480_zps30d8099d.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture486_640_x_480_zps30d8099d.jpg.html)

Also managed to remove some of the bracing, I can get in now to make repairs on the floor

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture490_640_x_480_zps145bb777.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture490_640_x_480_zps145bb777.jpg.html)

Before I left for home today, I threw the doors in the holes to see if they still fitted. They seem ok, if a little tight at the rear, but they did fit really badly when we first got the car

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture492_640_x_480_zpse471f7c6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture492_640_x_480_zpse471f7c6.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture493_640_x_480_zpsace6018b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture493_640_x_480_zpsace6018b.jpg.html)

Some more soon.

JB Chevy
26-10-13, 10:12 PM
Great work................. :tup: I honestly believe you have achieved the impossible so far. WOW :crazy:


27-10-13, 07:58 PM
Great work................. :tup: I honestly believe you have achieved the impossible so far. WOW :crazy:


Me Too

phunkie hiboy
29-10-13, 09:10 PM
Thanks guys.

Had a little bit of time to spare late Monday afternoon, bit bored with bodywork, so started looking at the front suspension.
Here’s both units and the difference can obviously be seen

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture494_640_x_480_zps4d33a841.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture494_640_x_480_zps4d33a841.jpg.html)

Stripping them down, the Midget one on the left and Met one on the right

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture496_640_x_480_zps2daf094e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture496_640_x_480_zps2daf094e.jpg.html)

From the photo it can be seen that the king pins are mounted differently to each other. The Midget one is mounted to the lower arm and goes up through the swivel/spindle assy. The Met one, however is mounted to the upper arm and goes down through the swivel/spindle assy. So, we need the Midget swivel and hub, the Met king pin and upper arm. The lower arm is the same in both cases and we already have new ones of those.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture497_640_x_480_zps77e45cb0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture497_640_x_480_zps77e45cb0.jpg.html)

To enable the Midget swivel to correctly fit the Met king pin, the bushes need to be replaced. In the States they have new ones turned up out of bronze or similar material

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/P1050540_640_x_480_zps2b412430.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/P1050540_640_x_480_zps2b412430.jpg.html)

And fitted into the swivel like this

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/NewBushingsInstalled_640_x_480_zps2a450964.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/NewBushingsInstalled_640_x_480_zps2a450964.jpg.htm l)

But what I discovered whilst carrying out the measurements on both swivels was that the upper bore diameter to carry the bushing was the same, and as I already have new Met bushes the top ones will fit straight in. The lower ones, however are larger, but if I remove just under 1mm out of the diameter of the old lower bush the new lower Met bush can be pressed in. I bought an adjustable parallel reamer on eBay last night, to do this job, and it should be here tomorrow. The final thing to do is ream out the new buses, but with no reamer (I have one for the Midget bushes but they’re a different size!! So as I have a second pair of Met king pins, I can use one of these to make a reamer to do the job. Just need to run an angle grinder cut the length of the king pin at an angle so that it makes a cutting edge. As new king pins aren’t available using a slightly worn pin as a reamer pays of because the king pins we’re going to use are slightly worn as well.
Some more once I done this little job!

phunkie hiboy
01-11-13, 07:16 PM
These are the stock replacement Met king pin bushes.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture498_640_x_480_zps47c84ca6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture498_640_x_480_zps47c84ca6.jpg.html)

The top bushes needed to be modified as the grease point on the Midget swivel is in a different place due to the calliper position. So just a slot to allow the grease to get to all of the bush and king pin.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture500_640_x_480_zpsc90d8136.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture500_640_x_480_zpsc90d8136.jpg.html)

With the top bushes in the lower original bushes were reamed out to take the stock Met ones.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture499_640_x_480_zps01d69a66.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture499_640_x_480_zps01d69a66.jpg.html)

And the lower bushes pressed in.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture501_640_x_480_zps0aa49018.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture501_640_x_480_zps0aa49018.jpg.html)

All in now

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture502_640_x_480_zpse4ef089c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture502_640_x_480_zpse4ef089c.jpg.html)

As the lower bush/king pin is the same diameter as the Midget one, I have a Midget king pin bush reamer, and the lead in before the cutting teeth is quite long, I installed the reamer in backwards. So just reaming the lower bush, not both.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture503_640_x_480_zpsfd3b914d.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture503_640_x_480_zpsfd3b914d.jpg.html)

Now, I haven’t got a reamer to do the top bushes, so I used an old spare king pin and cut some grooves in it.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture504_640_x_480_zps4c89cf50.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture504_640_x_480_zps4c89cf50.jpg.html)

This was then inserted right way in and after a fashion, it seemed to work. Once I’d gone right through it was still a bit tight, so I used fine valve lapping paste on the king pin (top end only) and a cordless drill attached to end threads, and effectively lapped the bush in.
So we now have a pair of rebuilt swivels ready for paint or powder coating, can’t make my mind up!!

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture505_640_x_480_zps97c4ec1e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture505_640_x_480_zps97c4ec1e.jpg.html)

phunkie hiboy
16-11-13, 09:50 PM
I’ve been waiting for some shims, so the king pin end float could be set up. Now these have arrived and the king pins/spindles have the right end float, they have been trail fitted.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture522_640_x_480_zpsa9cafffa.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture522_640_x_480_zpsa9cafffa.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture521_640_x_480_zpsbc9d339e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture521_640_x_480_zpsbc9d339e.jpg.html)

From these being fitted the length of the new brake hoses can be calculated. They needed to be about 1.5 inches longer with a banjo at the calliper end. I could have done this using standard BMC parts (banjo + adaptor + stock hose), but thought this might look a bit Walt Disney. So I called a buddy of mine, Guy (Bigyellataxi on here), he works for a hydraulics company (http://www.a1hydraulics.co.uk/flexible-hoses) and they’re going to make some original style hoses the right length and with the correct ends. Meanwhile the new callipers have arrived.

Back to the body, on the footwell sides under the wing there should be a strengthening panel. This would normally be part of the windscreen posts right to the forward edge of the footwell. The drivers side has one, but too short and no closed end and the passengers side, it was missing completely.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture508_640_x_480_zps3ddd8f7f.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture508_640_x_480_zps3ddd8f7f.jpg.html)

The box shape folded up

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture509_640_x_480_zps643040b6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture509_640_x_480_zps643040b6.jpg.html)

And the end result rust treated and epoxy primed. The forward end is not exactly as original, but as strong and less likely to trap mud and dirt.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture512_640_x_480_zps04736b17.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture512_640_x_480_zps04736b17.jpg.html)

Now with the passengers “A” post pretty much finished, the drivers side was finalised. With the strength now fully back in the shell the bracing was completely removed. The small repairs in the drivers side floor (front and rear) were then addressed and that side rust treated and epoxy primed.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture514_640_x_480_zps3a6296f4.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture514_640_x_480_zps3a6296f4.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture513_640_x_480_zps7548ed4b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture513_640_x_480_zps7548ed4b.jpg.html)

16-11-13, 09:55 PM
"Respect" Chris.:)

16-11-13, 09:56 PM
best build thread on here....top marks..:tup:

16-11-13, 10:12 PM
you could make a living doing this chris!

phunkie hiboy
30-11-13, 10:00 PM
Liam, I'm sure there are better ones.

Ian, you think?

A bit more in the bag, so to speak .....
Now to the passenger side, and the same, some small repair patches and a coat of rust treatment.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture515_640_x_480_zps81e5893c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture515_640_x_480_zps81e5893c.jpg.html)

Then a coat of epoxy primer.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture516_1024_x_768_zpsc29295ea.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/picture516_1024_x_768_zpsc29295ea.jpg.html)

Now the bracing has gone the rear “seat” panel can be reattached.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture517_640_x_480_zps608be8a0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/picture517_640_x_480_zps608be8a0.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture518_640_x_480_zpsd47bc595.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/picture518_640_x_480_zpsd47bc595.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture519_640_x_480_zps71e53e7e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/picture519_640_x_480_zps71e53e7e.jpg.html)

And now welded in with a coat of rust treatment.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture520_640_x_480_zpse89efa29.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/picture520_640_x_480_zpse89efa29.jpg.html)

01-12-13, 03:56 PM
you gonna have to re register this as a new car chris, as theres nowt left of the original one! great work attention to detail :tup:

phunkie hiboy
01-12-13, 04:20 PM
All being repaired to original using original parts or parts made to original spec. Or with parts from the late 50's/early 60's, so coevel. I even have a part number for the two rear wings and boot opening, as an assembly, available from your local Austin/Metropolitan dealer in 1960. :giggle:

16-12-13, 11:37 PM
Any updates?

phunkie hiboy
17-12-13, 09:04 PM
Any updates?

Not at the moment, Mark. Unfortunately, I don't have the luxury of being able to work on this project as a "full time job", unlike some. Customer cars come first. I haven't been totally idle, though. I'm going to get a chance to get back on it end of this week and Monday and Tuesday next week, and I'll do an update before Christmas, 'cos we're off to South Africa for a couple of weeks after.

phunkie hiboy
24-12-13, 03:48 PM
Now we need to put a coat of epoxy over the rear seat area.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture523_640_x_480_zps2ad767bc.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture523_640_x_480_zps2ad767bc.jpg.html)

The front hubs have now come back from re drilling to 5 on 4.5” and 7/16 studs.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture524_640_x_480_zps3ad94334.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture524_640_x_480_zps3ad94334.jpg.html)

Put some bearings in and fitted them up, to check out the new discs and callipers.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture526_640_x_480_zps235d0ffc.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture526_640_x_480_zps235d0ffc.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture525_640_x_480_zpsa6281dd8.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture525_640_x_480_zpsa6281dd8.jpg.html)

Only to find some issues with the bearing fit. Standard bearings for MG Midget front hubs are ball bearings, what we will be using are taper roller bearings. The ones that have been supplied us, as equivalent, have a smaller radius on the inner bearing than is on the spindle. This results in a gap, between the spindle shoulder and the face of the bearing, of about 0.020”. We could have the spindles machined with a smaller radius, but this will reduce the strength of the spindle and is likely to cause stress risers where the spindle and shoulder meet. I have heard cases where the spindle has actually snapped after carrying this mod out. So the inner ends of the inner bearings will be ground with a larger radius, which will solve the problem.

We also got some tyres on the rims now, whitewalls will be sorted out after the car has done about 1000 miles.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture527_640_x_480_zpsa6f4abae.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture527_640_x_480_zpsa6f4abae.jpg.html)

I went to remove the passengers side top spring cup, which is usually just a tight fit over a small raised spigot.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture529_640_x_480_zpsea5cc8d7.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture529_640_x_480_zpsea5cc8d7.jpg.html)

After the welds were removed and the cup turned upside down, this is what was found.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture530_640_x_480_zpsbdf6ba93.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture530_640_x_480_zpsbdf6ba93.jpg.html)

This is what it should look like (the drivers side).

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture531_640_x_480_zpsb56bd5f7.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture531_640_x_480_zpsb56bd5f7.jpg.html)

Think I’ll come back to that. The panel that the steering idler is bolted to on the passenger needs a bit of a cuddle. The main bolt that holds the idler had come loose at some point, broken its captivation and also broken out the hole for the second securing bolt and nut. This had been badly repaired.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture528_640_x_480_zpsc8aaf5a5.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture528_640_x_480_zpsc8aaf5a5.jpg.html)

Once the “repair” had been removed, this is what we had to work with.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture532_640_x_480_zps2d65750f.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture532_640_x_480_zps2d65750f.jpg.html)

phunkie hiboy
24-12-13, 03:49 PM
http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture534_640_x_480_zps62b4c6af.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture534_640_x_480_zps62b4c6af.jpg.html)

After bolting the idler on, as a guide.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture533_640_x_480_zps1db52aa3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture533_640_x_480_zps1db52aa3.jpg.html)

A more permanent repair was made.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture535_640_x_480_zps3696d5a6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture535_640_x_480_zps3696d5a6.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture537_640_x_480_zps91ed296e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture537_640_x_480_zps91ed296e.jpg.html)

Now turning our attention to the front of the “chassis” members, that had rotted out. These pieces contained tubes for the mounting of the front bumper irons.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture538_640_x_480_zps12cab413.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture538_640_x_480_zps12cab413.jpg.html)

The strengthening pieces were missing on both sides, so new ones were made and installed.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture540_640_x_480_zps18b7965b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture540_640_x_480_zps18b7965b.jpg.html)

And then replacement outer “chassis” pieces made and installed.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture541_640_x_480_zpsa8d3f5b7.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture541_640_x_480_zpsa8d3f5b7.jpg.html)

And on the other side as well.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture539_640_x_480_zpse5350e12.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture539_640_x_480_zpse5350e12.jpg.html)

At least the thing has now stopped creaking as the shell is revolved!!
Now back to that spring cup locator. Cleaned the area all round the damage and fabricated a tube set into a shaped flat plate.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture542_640_x_480_zps1d98ec45.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture542_640_x_480_zps1d98ec45.jpg.html)

And welded it in, also welding through to the gusset above, in the engine compartment.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture543_640_x_480_zps245deefc.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture543_640_x_480_zps245deefc.jpg.html)

phunkie hiboy
24-12-13, 03:49 PM
Then a blanking arrangement at the open end of the “tube”.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture544_640_x_480_zps219f569b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture544_640_x_480_zps219f569b.jpg.html)

And the spring cup fits back on perfectly, with out having to secure it with welds!!

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture545_640_x_480_zpsb727e278.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture545_640_x_480_zpsb727e278.jpg.html)

Now all the repairs to the inner wheel arches are complete, a coat of rust treatment is applied. I did want to get it in primer before Christmas, but have run out of time. At least the bare metal is protected, to an extent.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture546_640_x_480_zps1f53609f.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture546_640_x_480_zps1f53609f.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture547_640_x_480_zps40194edf.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture547_640_x_480_zps40194edf.jpg.html)

Well that’s it for 2013, back on it in the new year.

Merry Christmas and a Happy New Year to all our readers.

24-12-13, 04:44 PM
great thread

phunkie hiboy
24-12-13, 05:35 PM

phunkie hiboy
26-01-14, 01:43 PM
Right, so we’re back into it, now Christmas and our vacation is over.
The old captivation devices for door hinge screws left a little bit to be desired, so new ones were bent up.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture548_640_x_480_zpsa6c276ac.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture548_640_x_480_zpsa6c276ac.jpg.html)

And fitted.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture549_640_x_480_zps9d848a72.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture549_640_x_480_zps9d848a72.jpg.html)

Thought I’d try and get the lower portions of the front of the rear wheel arches sorted with fabricated panels. I did originally have a supply for these and the front wing ones, but now the guy doesn’t seem to want to supply them.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture550_640_x_480_zpsd0dc651a.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture550_640_x_480_zpsd0dc651a.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture551_640_x_480_zps44b65b94.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture551_640_x_480_zps44b65b94.jpg.html)

After exploring different options to do this, I realised that I had spare outer sill panels and that they were the right shape (curvature) for the lower part, so I would then just have to make a bridge piece.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture552_640_x_480_zps798615f5.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture552_640_x_480_zps798615f5.jpg.html)

Then fully weld and sand the panel. Just needs a bit of fettling and some filler to complete.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture553_640_x_480_zps55e38503.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture553_640_x_480_zps55e38503.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture554_640_x_480_zpsd7bbe103.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture554_640_x_480_zpsd7bbe103.jpg.html)

26-01-14, 11:24 PM
Good to see an update - been waiting! :)

26-01-14, 11:28 PM
i,ve been following this on ,MANKY MONKEY MOTORS, true dedication to restore to such a high standard :tup::tup::tup:

Slow & Low 400e
27-01-14, 02:07 PM
Just seen this build thread today.
It looked beyond repair and now it looks amazing.

27-01-14, 03:38 PM
Stunning work - fantastic :tup:

phunkie hiboy
27-01-14, 06:20 PM
Thanks guys.

i,ve been following this on ,MANKY MONKEY MOTORS, true dedication to restore to such a high standard :tup::tup::tup:

Just seen this build thread today.
It looked beyond repair and now it looks amazing.

So, does this make me a restorer!? :umpf: :giggle:

Slow & Low 400e
27-01-14, 11:03 PM
Thanks guys.

So, does this make me a restorer!? :umpf: :giggle:

Nah: restorers only repair things that are repairable. Got to invent a new category for you. :lol:

27-01-14, 11:07 PM
Nah: restorers only repair things that are repairable. Got to invent a new category for you. :lol:


JB Chevy
31-01-14, 08:16 PM

That'll do a treat... :D


phunkie hiboy
01-02-14, 05:13 PM
Thanks for that Mike & John, but your '55 is looking good. This is never going to be an award winner, it's just going to be a nice old drivable classic that's been a bit modified/rodded.

Well, I managed to get a couple of hours on it during the week and started fabricating the drivers side rear wheel arch front repair. Managed to finish it today, get some rust treatment on and shoot it with some epoxy primer.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture556_640_x_480_zpsb901ce88.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture556_640_x_480_zpsb901ce88.jpg.html)

And the passenger side in primer.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture557_640_x_480_zps96371ec1.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture557_640_x_480_zps96371ec1.jpg.html)

As today was bright, sunny and less damp than it’s been for a while, I thought I’d like to get the engine compartment and inner wings in primer, so spent a bit of time on that.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture558_640_x_480_zps4fb319f3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture558_640_x_480_zps4fb319f3.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture560_640_x_480_zps27d09fc2.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture560_640_x_480_zps27d09fc2.jpg.html)

With priming in mind, I sanded down the screen pillars, mounting edges and the area from the tops of the doors all the way from the front to the back. Rust treated and primed.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture559_640_x_480_zpsd365444a.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture559_640_x_480_zpsd365444a.jpg.html)

Whilst I was sanding the guttering, there seem to be rather a lot of paint layers. So I decided to carefully sand back a bit of the paint on the roof and found 8 layers of paint, starting from the original and ending with the last time it was painted.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture555_640_x_480_zps0d19a6d4.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture555_640_x_480_zps0d19a6d4.jpg.html)

As far as the shell goes there are just 3 areas to deal with now, The rear of the rain gutters, the joint on the “B” post between the roof and the post face and the area in front of the windscreen including the air duct for the heating, oh and get paint off the roof, that'll be 4 then. Start them next week. And then we start with the filling!!! :eek::scared:

Special When Lit
01-02-14, 06:42 PM

09-02-14, 08:48 PM
Have you seen this Chris and with a portafols

phunkie hiboy
09-02-14, 10:20 PM
Hi Mike, how are you?

Obviously this is in the states, hadn't really thought about Portafolds being out there. Here's a another picture of that one ..............

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/161900229_cd9e5aebb7_zps776f6a2e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/161900229_cd9e5aebb7_zps776f6a2e.jpg.html)

I also found pictures of another "phantom" met wagon, but haven't found one that I can post on here. In in the Berkshire green (light blue) and white colour way.

phunkie hiboy
02-03-14, 08:36 PM
OK, so here’s a small update. We’ve been moving house, so haven’t really been able to spend normal time on the car for a month now. Will be back on it again from next weekend though.
The battery box needed some attention and I thought it best to manufacture a new one, so got Fintan Ellis to fold up, in kit form, the sides and base. Will assemble these later.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture568_640_x_480_zps84b2e8e2.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture568_640_x_480_zps84b2e8e2.jpg.html)

Next I spent some time on the brake master cylinder mounting bracket. This is a picture of the original standard mounting bracket.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture563_640_x_480_zps81bdc941.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture563_640_x_480_zps81bdc941.jpg.html)

Looks plenty flimsy to me, so using some of the spare threaded holes in the chassis at that point, I made a strengthening bracket that could be removed should a purist ever own the car in the future!!

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture564_640_x_480_zps4097acf0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture564_640_x_480_zps4097acf0.jpg.html)

This will be powder coated before final fitting.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture565_640_x_480_zps0b09b99a.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture565_640_x_480_zps0b09b99a.jpg.html)

Whilst working on the brake pedal area, I made sure the pedal lined up with the hole in the firewall, it didn’t before.
I needed to get started on the steering column, so fitted it into the car with some of the accessories fitted (heater, brake pedal, wiper motor) and marked out the column.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture561_640_x_480_zps3c24e964.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture561_640_x_480_zps3c24e964.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture562_640_x_480_zps427fa99d.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture562_640_x_480_zps427fa99d.jpg.html)

Removed it and fabricated a jig.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture569_640_x_480_zps8df51e96.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture569_640_x_480_zps8df51e96.jpg.html)

What follows is a number of pictures, in sequence of a power steering addition using manufactured new parts from start to trial fit.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture570_640_x_480_zpsc88a5cf0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture570_640_x_480_zpsc88a5cf0.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture567_640_x_480_zps85a1a708.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture567_640_x_480_zps85a1a708.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture571_640_x_480_zps54608d0a.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture571_640_x_480_zps54608d0a.jpg.html)

phunkie hiboy
02-03-14, 08:36 PM
http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture572_640_x_480_zps1c9965f4.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture572_640_x_480_zps1c9965f4.jpg.html)

You’ll notice that even the original gear shift mechanism still fits in it original position and it functions perfectly. I will however need to fabricate a plate to fit under the wiper motor, which needs repositioning by about half an inch.

More later.

phunkie hiboy
09-03-14, 08:17 PM
Just a small update. Having removed the steering column and assembled it together permanently, refitted it back into the car and fabricated a couple of brackets to secure it (doesn’t really need it, because it is assembled as a complete unit). This is a picture taken from about half way up the window part of the “B” post and all that can be seen is a part of the motor and the torque sensor.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture573_640_x_480_zps80e4fd0e.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture573_640_x_480_zps80e4fd0e.jpg.html)

As I mentioned before the wiper motor requires moving a small amount to clear the EPS motor. Just needed to make an adaptor plate to reposition.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture574_640_x_480_zpse6bdb810.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture574_640_x_480_zpse6bdb810.jpg.html)

Then fit it to the motor …………

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture575_640_x_480_zpse7757597.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture575_640_x_480_zpse7757597.jpg.html)

And the whole assembly to the car.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture576_640_x_480_zpsa1df3abf.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture576_640_x_480_zpsa1df3abf.jpg.html)

Back to bodywork next week, to finish of the shell.

phunkie hiboy
10-03-14, 08:39 PM
I managed to find a couple of hours today, so I took some seam cappings that Fintan Ellis folded up for us …………

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture577_640_x_480_zpsc05d544d.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture577_640_x_480_zpsc05d544d.jpg.html)

These fit over some of the spot welded seams to make them look tidier and seal the seam from water ingress. First was the seam across the rear between the rear panel and the boot floor cross member.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture578_640_x_480_zps02f69575.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture578_640_x_480_zps02f69575.jpg.html)

Then the seams above the front footwells.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture579_640_x_480_zps4b1be348.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture579_640_x_480_zps4b1be348.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture580_640_x_480_zps3fbe17c9.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture580_640_x_480_zps3fbe17c9.jpg.html)

These will be seam sealed and undersealed later.

One job I’ve been avoiding is the air intake box for the heater blower

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture581_640_x_480_zpsad8ba0f1.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture581_640_x_480_zpsad8ba0f1.jpg.html)

Every time I’ve looked at it I couldn’t figure out what to do with it., so taking the bull by the horns I carefully drilled out all the spot welds that held it to the body and removed it.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture582_640_x_480_zps9fd4a9e0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture582_640_x_480_zps9fd4a9e0.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture583_640_x_480_zpse159fcd7.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture583_640_x_480_zpse159fcd7.jpg.html)

As you can see, it needs a bit of a cuddle. So carefully drilling out the spot welds, we ended up with three separate pieces which can now be blasted before reassembling and refitting.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture584_640_x_480_zpsfc891326.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture584_640_x_480_zpsfc891326.jpg.html)

phunkie hiboy
16-03-14, 10:16 PM
Haven’t been able to do too much since the last update, but the heater blower plenum has now been sand blasted, reassembled, rust treated and epoxy primed. Now ready to be re welded back into the car.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture585_640_x_480_zps4c73c409.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture585_640_x_480_zps4c73c409.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture586_640_x_480_zpsfd0902e2.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture586_640_x_480_zpsfd0902e2.jpg.html)

phunkie hiboy
17-03-14, 11:06 PM
Managed to find a bit of time to take the doors to the media blasters this afternoon, should have them back next week sometime.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture587_640_x_480_zpse72ee895.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture587_640_x_480_zpse72ee895.jpg.html)

phunkie hiboy
23-03-14, 08:50 PM
Managed to do a little more this weekend. The panel in front of the front screen required some attention, so with the repairs done, the heater blower plenum welded back in and some rust treatment, the area was shot with epoxy primer.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture588_640_x_480_zpsbd1604e6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture588_640_x_480_zpsbd1604e6.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture589_640_x_480_zpsa5d4ff14.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture589_640_x_480_zpsa5d4ff14.jpg.html)

I also made some wiring/pipe securing tabs. A lot of the original ones were broken, rust and repeated attaching pipes/wiring looms make them weak. So they’re just little tabs of metal with a hole at one end to be rosette welded on

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture590_640_x_480_zps320970c4.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture590_640_x_480_zps320970c4.jpg.html)

I thought that while I was collecting the doors from the media blasters, next week, I’d drop some more bits off to be depainted.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture591_640_x_480_zps80d7633b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture591_640_x_480_zps80d7633b.jpg.html)

I managed, this week, to take some pictures of the rear most part of the roof gutters, (on the car that I’m using for reference) so that I know how to finish ours off. More than likely be done next weekend.

phunkie hiboy
06-04-14, 06:20 PM
Well, not much happening that makes it look like it’s moving forward. This weekend I’ve done a total parts inventory, we’ve pretty much got all the big parts, but some of the smaller parts need sourcing.
Last week, I managed to get the battery box assembled and welded. As this is a bolt in part, it can be fitted later.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture592_640_x_480_zps0f7cd44d.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture592_640_x_480_zps0f7cd44d.jpg.html)

And at last the new rear hubs have arrived, together with the re drilled brake drums. The original hub is to the left at the back. The new ones will enable us to fit those lovely 5 stud Radirs.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture593_640_x_480_zps45a7a11b.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture593_640_x_480_zps45a7a11b.jpg.html)

06-04-14, 06:49 PM
Nice bit of work going on there, thought this was just a get it nice not show condition:lol::tup:

07-04-14, 01:52 PM
Agreed, a very kool little build.

phunkie hiboy
08-04-14, 06:33 AM
Nice bit of work going on there, thought this was just a get it nice not show condition:lol::tup:

This isn't and never will be a 100 point restoration, would have chosen a better base car than this. :happy:

Had a little bit of time to do a couple of bits yesterday.
As we’ve taken the clutch pedal out, something had to take its place on the shaft. To add some strength into the pedal shaft area I made this,

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture594_640_x_480_zpsbc0b4727.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture594_640_x_480_zpsbc0b4727.jpg.html)

Which fits in like this.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture595_640_x_480_zpse3dd9281.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture595_640_x_480_zpse3dd9281.jpg.html)

Also collected the doors from the blasters (dropped some more bits off)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture596_640_x_480_zpsadbc30b9.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture596_640_x_480_zpsadbc30b9.jpg.html)

And gave them a couple of coats of epoxy primer.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture597_640_x_480_zps1f032bbf.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture597_640_x_480_zps1f032bbf.jpg.html)

phunkie hiboy
12-04-14, 09:55 PM
Got a couple more things sorted this weekend. The gearbox is due to go away to be rebuilt, after Easter. This particular generation of BW35 box doesn’t have an oil cooler and as we’re likely to tow the Portafold, we need one. The fitment is quite easy, After the sump and valve body is removed the casing is drilled in the right place (there are two bosses cast into the casing) and tapped the right thread for the adaptors to be screwed into. I have another box (out of a Stag) which I removed the cooler pipe from the front pump to the front adaptor and fitted it to the “Met” box, fitted the valve body and sump back. Then test fitted the new cooler pipes (managed to find a company on the net that makes sets of brand new Rover V8/BW35 trans cooler pipes).

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture598_640_x_480_zps05b108f3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture598_640_x_480_zps05b108f3.jpg.html)

Today I started to fit doors. After refurbishing the hinges with new pivot pins and fitting them to the drivers door, the door was fitted to the body shell. After a bit of shimming we’ve got to the best position for the moment, still got to carry out the patch repair all along the bottom, so still a bit floppy.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture599_640_x_480_zps587d94a3.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture599_640_x_480_zps587d94a3.jpg.html)

JB Chevy
16-04-14, 06:36 PM
Still marching ahead, looking like a car now....... top job and a gold star for perseverance :tup:


phunkie hiboy
16-04-14, 08:57 PM
Thanks, how's yours coming along, John?

Nigel Incubator-Jones
16-04-14, 10:28 PM
That looks like it's coming along well. Nice cars, Metropolitans.

phunkie hiboy
20-04-14, 03:53 PM
Thanks for that Zack.

Well haven’t got a lot done this weekend. Wheels day Friday and family stuff to do today and Monday. Not too much done Saturday with all the visitors to the shop, one, Charlie Turner, all the way from Cape Town. He’s an English guy who moved out to the Western Cape and runs, with his partner, a guest house, check it out here …… http://www.thecoachhouse.co.za/
He has a couple of classics, including a Met convertible (picture’s not too good, but you get the idea)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/img001_640_x_480_zps0af49708.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/img001_640_x_480_zps0af49708.jpg.html)

The radio set up that we’ve bought for the car enables the controls to fit where the originals did (very wide fitting), but is fully electronic (including controls) has Bluetooth and USB sockets for Ipod & memory stick.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture600_640_x_480_zps5f65a574.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture600_640_x_480_zps5f65a574.jpg.html)

The original radio was complete with a mono speaker in the centre (bit like an early portable radio) and a louvred grille to cover it.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture601_640_x_480_zps22a4cc32.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture601_640_x_480_zps22a4cc32.jpg.html)

It would be impossible to fit the radio in the original place and be able to use the buttons. We worked out that if the louvers were cut out, the radio together with a small panel to hold the USB sockets would fit.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture602_640_x_480_zpsd11cd5da.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture602_640_x_480_zpsd11cd5da.jpg.html)

But it would have to stay that way when not in use. With a little more thought and a sliding tray under the radio unit powered by a small motor, it could be made to retract. So now we’re looking for another but complete speaker grille to use as a flap/cover. This is where Charlie came in. He had just re installed and original radio (updated to FM) and had to replace part of the dash where two gauges had been fitted. For this he had bought, from the states, a small part of a dash. He used what he needed from the dash piece which left the louvred grille untouched. And this is what he bought me from South Africa.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture603_640_x_480_zpsbc7ca6ec.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture603_640_x_480_zpsbc7ca6ec.jpg.html)

So keeping the raised portion, round the outside, intact, I cut the grille out and shaped the corners.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture604_640_x_480_zps64448a9c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture604_640_x_480_zps64448a9c.jpg.html)

And now in front of our dash …….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture605_640_x_480_zpsec513168.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture605_640_x_480_zpsec513168.jpg.html)

And finally positioned where it will be fitted. All I have to do now is build the operating mechanism for the radio tray/slide and the grille panel.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/picture606_640_x_480_zps21555a45.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/picture606_640_x_480_zps21555a45.jpg.html)

So I did get something done this week, even if it was a small item, we’re still moving forward. And I wouldn’t have been able to do this without Charlies help,thank you. This is becoming a global car now!!

08-08-14, 08:59 PM
Been a little quite ..... whats been happening

08-08-14, 09:43 PM

Whats happening with the old phunky thing?

phunkie hiboy
10-08-14, 04:40 PM
Well guys, thanks for asking. Some one dropped a '50s Chevy truck into the shop, straight from the docks and asked me to do a complete check over so when it was registered it would be fit for the road. It arrived and what was 'sposed to be a daily driven vehicle, well it was like a fairy tale. There is no way this was a daily, in fact it was dangerous, even in the States. This was supplied by a used car dealer in California run by an English man!!
So I've had to concentrate on that, as it's a friends truck. Should be finished and MOTd in the next week or so. We can get back on the Met again then. I'd love to see it done as well!
We've been buying parts still, along the way.

10-08-14, 07:02 PM
Well guys, thanks for asking. Some one dropped a '50s Chevy truck into the shop, straight from the docks and asked me to do a complete check over so when it was registered it would be fit for the road. It arrived and what was 'sposed to be a daily driven vehicle, well it was like a fairy tale. There is no way this was a daily, in fact it was dangerous, even in the States. This was supplied by a used car dealer in California run by an English man!!
So I've had to concentrate on that, as it's a friends truck. Should be finished and MOTd in the next week or so. We can get back on the Met again then. I'd love to see it done as well!
We've been buying parts still, along the way.

bet i know who the ,california,,used car dealer,,, is :shake: not the 1st time i,v heard about his ,,it was in daily use,,, got one here ,,,

phunkie hiboy
10-08-14, 07:21 PM
Yeh, had a long PM conversation with Jimmy the other day.

phunkie hiboy
16-02-15, 07:56 PM
Sorry it’s been so long coming, but now I have all the major
project, customer cars out of the workshop I can do a bit more to this little project!!
Needed to find something smallish to do in the couple of days leading up to our holiday, which we’ve just come back from.
Easiest, in terms of reasonably quick to do was the front/grille panel. I haven’t got any pictures of it on its own, but it has been media blasted and there are a number of issues that have surfaced.
Both ends are in need of attention, so we’ll start with the left side.
This is what we’ve started with ………….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpslzlimatv.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpslzlimatv.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsg0qw9hnz.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsg0qw9hnz.jpg.html)

The return has been removed and a two inch strengthening piece spot welded all the way down, a new return fabricated and welded on.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zps78msrx4v.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zps78msrx4v.jpg.html)

Showing the final cleaned up portion, with half side light hole cut.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/010_640_x_480_zps4jcdfwft.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/010_640_x_480_zps4jcdfwft.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/009_640_x_480_zpsrmickbjy.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/009_640_x_480_zpsrmickbjy.jpg.html)

Now to the other side, which is a bit more difficult.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zps86yu0cqp.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zps86yu0cqp.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zps86yu0cqp.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zps86yu0cqp.jpg.html)

I cut this piece off.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpshtjbsvh2.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpshtjbsvh2.jpg.html)

And added a two inch strip behind as with the left side.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zps98q1vtk5.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zps98q1vtk5.jpg.html)

Then a piece over the top.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpso42b1jsk.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpso42b1jsk.jpg.html)

Finally welded on the new fabricated return.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/007_640_x_480_zpswhzbuphg.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/007_640_x_480_zpswhzbuphg.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zps2olttugm.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zps2olttugm.jpg.html)

Fabricate new upper part/headlamp lower ¼ section, joggle fitted as opposed to the original that had only 9 spots of braze holding it from top bottom! All the bare metal bits were painted with rust inhibitor.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zpsdhte51g4.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zpsdhte51g4.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/009_640_x_480_zpsojhoyk6u.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/009_640_x_480_zpsojhoyk6u.jpg.html)

Finally a coat of epoxy primer to protect it.

phunkie hiboy
16-02-15, 07:56 PM
I still have some work to do on this, capping of the bits next to the head lamp potion and some hammer work on the dented bits.
After removing the rotisserie front portion, the front panel and the panel behind were fitted. This is needed to be done to enable the wings to be offered up.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpsrunxjq27.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpsrunxjq27.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpsslgk5p3x.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpsslgk5p3x.jpg.html)

16-02-15, 09:56 PM
Great to see an update - that front panel looked pretty bad!

phunkie hiboy
17-02-15, 07:34 AM
Yeh, it was. Good body parts are difficult to source here, no new ones available. Difficult to obtain from the States 'cos you'd probably have to go and cut them off for yourself, so you have to do the best you can.

bully madhatter
18-02-15, 11:31 AM
I have just read this and all i can say is wwwoooowwww...... and I thought I had maybe bitten off more than I can chew.

phunkie hiboy
07-03-15, 03:09 PM
Thanks for that Graham.

I’m still managing to fid small bits to do, between customer jobs. Here’s another small job that needed doing at some point.
The gearbox cross member is rusty, bent and has been repaired before.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zps6y5kntp4.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zps6y5kntp4.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsuuwmrsl6.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsuuwmrsl6.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsqbaounwz.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsqbaounwz.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zps5ypicojk.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zps5ypicojk.jpg.html)

You can get new ones of these but they’re around the £200 mark!! First thing to do is to remove the damaged parts.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zpsxcckcv1m.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zpsxcckcv1m.jpg.html)

Then fabricate some new repair panels.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/007_640_x_480_zpsuht1tx8a.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/007_640_x_480_zpsuht1tx8a.jpg.html)

Then the original part to the blasters, to get rid of the rust.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpsqib56oex.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpsqib56oex.jpg.html)

Fit and weld on one end.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpsmrz19zsl.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpsmrz19zsl.jpg.html)

And clean up the welds.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsvyml42hv.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsvyml42hv.jpg.html)

And with the other end on, it’s complete and ready to have powder coated.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsoe0pngce.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsoe0pngce.jpg.html)

07-03-15, 04:39 PM
lovely work :)

phunkie hiboy
07-03-15, 05:25 PM
Thank you, Dave

Henrys Revenge
07-03-15, 08:45 PM
I love the little Met your doing a great job :tup:

I just got an ansfold Ive been reading your build on your portafold its looking great

07-03-15, 09:30 PM
very nice

phunkie hiboy
09-03-15, 09:18 PM
Thanks Gary, are you going to the portafold gathering in August?

Thanks Dal, how are you?

Had a spare hour or so today. Started out bolting in some of the super structure around the radiator area, so I could fit a couple of front wings on.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpskkeejybz.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpskkeejybz.jpg.html)

Then took the doors off and sorted out the best wings to fit. I had the original ones off the car, but I also bought a pair from eBay a while ago. The eBay right wing was better than the original, looks like it had been replaced, as the metal is really thick and there are no holes for the Met script on the side.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsiypos63r.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsiypos63r.jpg.html)

It topped up that the left wing that came off the car was better than the eBay one, again it looked like it had been replaced sometime in its life.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsrnprvfcd.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsrnprvfcd.jpg.html)

The white area is filler and paint. When it was blasted, they were having hastles removing this, so I had it back and am sanding it off with a grinder. Once the filler’s all gone, the wing is repaired and the dents are gone, I’ll take both wings back and have them lightly reblasted.
The wings line up remarkably well, with identical door hole sizes and they sit at pretty much the same height to the tops, so not too much adjusting to be done!!
This is how it looks from the front now.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zpsvnikovcf.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zpsvnikovcf.jpg.html)

09-03-15, 09:33 PM
its taking shape now chris,looks like a car again

09-03-15, 09:43 PM
Great stuff.
I am always in awe/envious of people who can do this sort of thing.
Always wanted to learn to weld...maybe this year....

phunkie hiboy
10-03-15, 07:43 AM
its taking shape now chris,looks like a car again

Yeh, it is Stretch, but I don't think it'll make Wheelsday this year!!

phunkie hiboy
10-03-15, 07:45 AM
Thanks mopar. Just buy yourself a cheap welder and practice on bits of off cut metal.

10-03-15, 05:40 PM
Yeh, it is Stretch, but I don't think it'll make Wheelsday this year!! ha ha . theres never enough time in the day!

steve 5-6-7 & 62
10-03-15, 06:41 PM
Yeh, it is Stretch, but I don't think it'll make Wheelsday this year!!
Not much has !

10-03-15, 06:52 PM
I very well Chris and your good self you ok. your work is fantastic . the car did n`t look that bad in the first photos,it look like it only needed a couple of bit`s and pieces .man that's a shedload of work you `v e had to do. Wow:tup:

10-03-15, 07:04 PM
Not much has ! ha ha you took the words out of my mouth,you said what i thought steve

Henrys Revenge
01-04-15, 06:59 PM
Thanks Gary, are you going to the portafold gathering in August?

I sold it already :shake:

I have a proper hot rodded caravan in the making tho

phunkie hiboy
17-04-15, 08:15 PM
Sorry it’s been a while, but sorting the wings out have been a bit of a nightmare. The left hand wing had issues around the headlamp and down the front to the lower edge.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsg90arj6a.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsg90arj6a.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsw9s7bltv.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsw9s7bltv.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpsriq9tngt.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpsriq9tngt.jpg.html)

Loads of work, with two and three compound curves running down the front. I’m not going to show the jigsaw of new metal that has gone into this wing, but suffice to say it is now serviceable and solid.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsa2gj6hnc.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsa2gj6hnc.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zps3k82wzxd.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zps3k82wzxd.jpg.html)

The right hand side is a bit more of a puzzle. It fits really well at the back and to the inner wing, but at the front, around the indicator the shape is all wrong. Looks like the bumper has been forced into the wing, cutting it.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsys1esvbt.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsys1esvbt.jpg.html)

The gap under the headlamp is a concern.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zpsdt0nwnxz.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zpsdt0nwnxz.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zps4v2ighzc.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zps4v2ighzc.jpg.html)

Need to consider my options here, might be a while!!

phunkie hiboy
17-04-15, 08:39 PM
Meanwhile, there are other things going on in the back ground. Small bits that will eventually need addressing. One of which is the air filters.
A while ago I bought a pair of Option air filters for an MGA. These are from the ‘50s and were made just round the corner from here at Vokes filters at Normandy (nr Guildford).

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpsdimy3w36.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpsdimy3w36.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpsnta7vqog.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpsnta7vqog.jpg.html)

When I bought the carbs, they came with a pair of ‘50s/’60s bell mouths.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsbsn63yta.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsbsn63yta.jpg.html)

These would not fit over the fixings for the filters.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/007_640_x_480_zpsn2s60ytl.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/007_640_x_480_zpsn2s60ytl.jpg.html)

So some careful modifying of the bell mouths.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zpsvv2m0isu.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zpsvv2m0isu.jpg.html)

Allowed them to slip over the fixings.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zpsddpqgahi.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zpsddpqgahi.jpg.html)

However using the filter elements that came with the filters would have maybe caused a reduction in air flow into the carbs.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zpsaajiryds.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zpsaajiryds.jpg.html)

So some threaded bosses were turned up, to add another 1” of air gap/filter thickness to the filter element.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/009_640_x_480_zpsovtzjdq1.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/009_640_x_480_zpsovtzjdq1.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/010_640_x_480_zpsa4hvisry.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/010_640_x_480_zpsa4hvisry.jpg.html)

I now have some thicker K & N filters on the way, which will work well. Just got to source some period looking expanded steel sheet the fabricate the “grilles that go round the filter elements.

phunkie hiboy
17-04-15, 09:10 PM
One other thing the I had been mulling over for a while now is the bonnet mascot.
There was an accessory mascot available in the late ‘50s early ‘60s. This was in the shape of the mascot that was standard on the ‘53/’54 Nash Rambler.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/Sunning_by_MSJames_640_x_480_zpsfdjogqf0.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/Sunning_by_MSJames_640_x_480_zpsfdjogqf0.jpg.html)

I think that this particular mascot looks to “heavy” for the car, so we chose the mascot from a ‘55 Rambler instead.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/SuperStock_4093-6227_640_x_480_zpsmndkfzs2.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/SuperStock_4093-6227_640_x_480_zpsmndkfzs2.jpg.html)

To me the whole thing looks lighter and more sleek.
So we bought one off US eBay. These couple of pictures aren’t the actual one, but are in a similar condition with pretty bad pitting.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/woman204_640_x_480_zpsqwoioyjg.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/woman204_640_x_480_zpsqwoioyjg.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/T2eC16dHJFoE9nh6pi5WBQGtH6gHNw60_3_640_x_480_zpsli xyyrgt.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/T2eC16dHJFoE9nh6pi5WBQGtH6gHNw60_3_640_x_480_zpsli xyyrgt.jpg.html)

I was still concerned about the physical size of the mascot and how it didn’t seem to be in “scale” with the rest of the car!
I did some calculations and discovered that the Metropolitan is about 25% smaller than the Rambler. To put that into context, we need the mascot to be 25% smaller.
So I made some enquiries around a few companies that dealt with 3D scanning and printing (can you see where this is going).
Sometime before Easter I took the old mascot into CDG in Alton for them to work their magic. So to scan it, remove all the pitting, reduce it by 25% and print it out into a plastic “mascot” that we can use to get it cast up by the use of lost wax investment casting.
This is what they sent me, by email, about a week and a half ago ……….

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/Holes2_zpsvf3cn70w.png (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/Holes2_zpsvf3cn70w.png.html)

Just got to wait now, for the phone call to say it’s ready for collection!!

phunkie hiboy
18-04-15, 01:22 PM
After a bit of thought about the right hand front wing below the head lamp, I decided to cut the corresponding piece from the original wing and weld it into the new one.
Remember I had bought another pair of wings and am now using the best two out of four. I didn’t really want to use any parts from these, as they might be of use to someone else in the future, still needs must.
So, I’ve cut the part I need out of the old wing.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/005_640_x_480_zpsopnvnaby.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/005_640_x_480_zpsopnvnaby.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zpsutslbivl.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zpsutslbivl.jpg.html)

Welded a new return on it, around the side lamp area.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/001_640_x_480_zpsmzaxhknb.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/001_640_x_480_zpsmzaxhknb.jpg.html)

This is the area I need to replace.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/002_640_x_480_zps2mmdsufr.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/002_640_x_480_zps2mmdsufr.jpg.html)

Marked out and cut about ¾” inside the fixing line, joggled the edge so that the “new” part fits level.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/003_640_x_480_zpso7kemxx2.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/003_640_x_480_zpso7kemxx2.jpg.html)

Made holes, in the “new” panel, for rosette welding into the wing.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/004_640_x_480_zpsitr8aebg.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/004_640_x_480_zpsitr8aebg.jpg.html)

Clamped on and welded, welds cleaned up and this is what it looks like now.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/009_640_x_480_zpsj0dxor2c.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/009_640_x_480_zpsj0dxor2c.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/006_640_x_480_zpsl1kdjmna.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/006_640_x_480_zpsl1kdjmna.jpg.html)

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/007_640_x_480_zpsqnq9o6hh.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/007_640_x_480_zpsqnq9o6hh.jpg.html)

You can also see how far out from the panel line the repair patch is on the valence part of the wing.

http://i781.photobucket.com/albums/yy95/phunkie_hiboy/metamorphosis/008_640_x_480_zpstuvc6qam.jpg (http://s781.photobucket.com/user/phunkie_hiboy/media/metamorphosis/008_640_x_480_zpstuvc6qam.jpg.html)

Back with some more soon.

18-04-15, 09:18 PM
Is that the same as spot welding, cant even see your welds there, just wondering how you fill the gap in now

Cant tell the n/s wings been repaired from your pics, good stuff :tup:

phunkie hiboy
19-04-15, 07:42 AM
Kind of Kev, with spot welding you hold the panels, to be welded, between a pair of copper tips supplied with a current (it's basicly a safe dead short) which heats the metal into each other, in that spot. Rosette welding is where one of the two pieces of metal has small holes punched in it, the two bits of metal are clamped together and a mig welder is used to weld into the holes. Then you just sand the excess weld off.
The gap will be welded and shaped with a hammer and dolly a small length at a time. Then sanded off.

19-04-15, 07:44 AM
We always called it plug welding. Lot of work around the front end.:umpf:

phunkie hiboy
19-04-15, 08:27 AM
S'pose it comes from the situation where you have maybe two bits of tube, one inside the other. You don't want to weld round the end of the bigger tube, so you drill a hole about 1/3 the diameter of the tube (large tube) slide the tube over and weld through the hole into the inner tube. This would require you to lay the beads in a circular fashion, making it look like a rosette. I get your point though, Gerry, I have heard of it called plug welding.
The silly thing about the front end is that I saw a pair of wings for sale on eBay, for 50 bucks each (no money in the big scheme of things), in Arizona. From the photos they were in excellent original condition, needing nothing but media blasting. Contacted the guy about shipping, and he wanted 300 bucks to ship them to New Jersey, which I baulked at then. Wish I'd bought them now!!

10-08-15, 09:06 PM
Kind of Kev, with spot welding you hold the panels, to be welded, between a pair of copper tips supplied with a current (it's basicly a safe dead short) which heats the metal into each other, in that spot. Rosette welding is where one of the two pieces of metal has small holes punched in it, the two bits of metal are clamped together and a mig welder is used to weld into the holes. Then you just sand the excess weld off.
The gap will be welded and shaped with a hammer and dolly a small length at a time. Then sanded off.

Hows the car coming along

Given us an idea on how to try something with that Rosette welding :tup:

phunkie hiboy
10-08-15, 10:04 PM
Have done small bits on the front wings that don't warrant updating on here, Kev, but customer jobs keep getting in the way. :grr: