A restoration in pictures and words

[38F3E1]

Thought I would start a words and picture restoration thread for my 1973 2.4E. It's going to be rebuilt as a fast road car that can be used for competition (probably sprinting) rather than a museum piece. The inspiration would probably the Gruppe R cars you see over in the US. Purists should probably not follow this thread as this car is not going to have all the correct bits on it ...

The overall goal is that the car is absolutely solid, usable and fun after the restoration because I don't want to have to this again in the next ten years. The car is being built to drive and has a target weight of 900KG (challenging but will try damm hard) with priority to getting it off the rear of the car. Because it will be used occasionally for track and competition events sensible changes will be made (such as seam welding in places) to prepare the car for this. The other goal is to try where possible not wreck it's integrity as a 73E shell. There'll be a lot of lightweight parts going on it but where possible this will be done without changing the shell design.

Reference material such as the factory R/ST/RS/RSR modifications of the period, Bruce Anderson's books, etc are being used as guidelines in the design.

 

[38F3E1]

Car has been stripped down and the shell has been dipped to remove all the paint to see what's what.

Rather than great areas of rust and disintegrated panels the shell is generally solid but with many small localised areas of perforation caused by rust. This sort of work is not something most bodyshops will touch because the level of fettling is just too detailed for them. They shake their heads and suck their teeth. They like to weld large panels. Fortunately I have access to somebody who can.

There are some big bits though too. Major areas needing attention are sills, floor edge, a-post, scuttle. The rear chassis has some existing patches on it that need checking (and maybe replacing) plus a couple of other areas on it to sort.

 

[38F3E1]

Here are some general pictures of the shell.

nice to see the car still has it's original roof

 

[38F3E1]

This is typical corrosion

and some previously badly repaired bits that need doing properly

 

[38F3E1]

Panels identified as needing to be purchased and fitted so far are outer and middle sills both sides, drivers a-post, scuttle panel, floor edge repair panel drivers side, rear anti-roll bar mounts both sides, fuel pump mount (cut off to mount rear anti-roll bar passenger side), engine rubber skirt channels both sides.

In these two pictures you can see the floor edge has already been dealt with on the drivers side by letting in a new replacement section.

A view from the top

A view from the bottom

The new panel has not been attached at the sill end yet as these are still to come off and be replaced.

 

[38F3E1]

There are lots of bits where it's not worth replacing a whole panel, instead patches need letting in

Also the car has accumulated an enormous amount of holes drilled in it over the years. Wish I knew why! Each one is filled by cutting a small metal disk and welding it in. Here's some welded in and awaiting grinding flat for finishing

 

[38F3E1]

Here's a new rear anti-roll bar mount tacked up ready for final checking. Note the fuel pump bracket had to be cut off to do this so a new one will be put back on.

Once they are properly on they will be strengthened by welding on a front piece to triangulate the fitting.

Here's the rear roll cage mounting

 

[38F3E1]

Everything so far has been done without a jig as the work so far has been small non structural repairs. The shell has been measured and is pretty straight so a lot of the general work can be undertaken without a jig.

Another couple of weeks and we get to the proper structural stuff. The sills, a-posts and scuttle will be cut off, the car will then be put on the jig and pulled as required to be dead straight. The new sills, a-post and scuttle will then be fitted whilst on the jig plus the fixing of the previously badly repaired front nose panel.

I'll post more pictures at that stage

 

[cococola]

This looks a great project............. good luck I will follow any updates with interest[]

 

[Mark_Bennett]

Wow.
Without people like you there would be less of these cars around []

 

[daro911]

Very interesting and equally exciting piece of motoring history developing before our lucky eyes I shall watch out for the next instalment ... Any idea of when the wheels will be turning in anger again and whats the final colour scheme []

 

[38F3E1]

Completion sometime in 2007. Summer would be great if it can be done by then. Vague I know ...

As for colour ... car left the factory as Silver Metallic with black cord interior. Therefore this has to count a lot in the decision as to what colour to paint it but I have been unable to come to a final decision yet.

 

[daro911]

ORIGINAL: ian_uk

Completion sometime in 2007. Summer would be great if it can be done by then. Vague I know ...

As for colour ... car left the factory as Silver Metallic with black cord interior. Therefore this has to count a lot in the decision what colour to paint it but I have been unable to come to a final descision yet.

[8D] Please don't paint it in the factory colour scheme otherwise I fear I will be forced to make you an offer you can't refuse and I can't afford []

 

[Nick Moss]

Hi Ian

That is quite a project, good luck with the progress. Was the shell stripped of paint and sealer by acid dipping or by pyrolisis?

 

[912UK]

Nice Welding BTW..

 

[38F3E1]

Nick.

It was done by Surface Processing in Dudley if that answers your question. Went for the strip only, no coatings on afterwards. Once all the bodywork is complete we'll do a quick dry fit of all the parts on it, then send the shell back to them for a re-dip to remove any surface rust and get them to e-coat it.

 

[pmjt]

Nice work Ian - as you say, too many bodyshops will simply cut out an entire panel and do BIG welds - I also have a guy who is well versed in plug and butt welding who likes the challenge of leaving as much of an original panel in place as he can.

Thanks for the photos [] And do keep us up with your progress - Good Luck []

Philip

 

[38F3E1]

Here are some more pictures

The anti-roll bar mounts have now been strengthened. Not particularly elegant but hopefully it will stop them breaking

Here's the rear part of the roll cage being fitted

 

[38F3E1]

The front has been sorted including removing the battery boxes. With a modern small gel battery these will not be required. All the welds are still to be cleaned up.

A new captive nut required for front petrol tank mount ... previous had pulled out!

 

[38F3E1]

New A-Post mounted. Notice how bad the corner of the scuttle is at the top of the post

The scuttle corner is really horrible. It has three layers, outer, middle and inner in a sandwich layout. A lot of work here to rebuild it properly. Lot's of curved pieces and flanges to form.

This shows a new piece let in at the dash end

Finally work has started preparing the new scuttle. As the only one available has the later window washer slots these have to be welded up and original holes drilled. The whole of the old scuttle is in the process of being removed.