RESTORATION OF BE646 2011 - TO DATE (26 December 2023/MSG 423)
SUBJECT INDEX
# = message number (p. x-y) = number of photo in separate linked pages at
https://c.1und1.de/362516207/Qk7IjtyMTCmCqPrexFGo5A PART 1/2
Battery Box
#321: battery tray
#323: battery tray fitting
#363: battery tray attached
Body Panel Repairs
#189 (p. 276): stripped body
#192: stripped body
#210 (p. 332-333): discussion about removing roof and rear of body
#318: stripped car with rear and roof remaining over frame
#192 (p. 278-280): stripped body including inside roof above doors
#317: “exploded” panels
#196 (p. 287): reproduction VIN plate
#403: chassis plate mounted
Body reconstruction #335: beginning reassembly
#377: body refitted on frame
A Pillars #315: A pillar repairs
#327: A pillar reconstruction
#333: body panels below A columns
B Pillars #40 (p. 43): right door jamb
#65 (p. 68-69): door jambs
#226: B pillar braces
#232-233 (p. 385-393): B pillar repair
#234-238 (p. 394-400): B pillar bracing panels
#239-244: B pillar bracing panels
#247 (p. 406-410): better B pillar covers and bracing
Bonnet #157: before and after repairs
#371: rebuild and installation
Boot (trunk) panels #46: repairs needed
#285-291: making panels for boot
#294: old and new boot panels exploded
#303: boot panels
#305: boot panels and spare wheel cover
#368: boot panels including floor
Fender panels and screens #304: rear inner fender wing panels
#305: inner front fender screens and wing panels
#314: inner fender panels in front of radiator
#321: removable inner front fender liners
#368: internal rear fender panels
#389: rear fender undercoat discussion
#398: inner front fender liners and mounts
#399: front fender stone guards
Floor Panels #283: floor panels
#303: floors (Zephyr)
#313: stronger floor panels (for Zephyr transmission)
Panel behind seats #25 (p. 20-21): panels behind seats
#225 (p.366-369): fitting fiberglass panel
#251 (p. 420-422): fiberglass panel behind seats
#293-294: brackets to attach the panel behind the seats
Rain gutters #392
Rear Body Panel Replacement #213
Rocker (Door Sill) Panels #206: sill repairs
#222-224 (p. 356-366): right and left door sill repairs
#231 (p. 380-385): rocker panel repair and replacement
#245 (p. 400-403): rocker covers
#303: rocker fitting
#316: rocker panel reconstruction
Transmission Tunnel #282: transmission tunnel
#283: transmission tunnel
#313: transmission tunnel (for Zephyr transmission)
#359: return of complete body from body shop
#359: location and installation of front turn signals and bumper with overriders
#384: new transmission tunnel
Brakes and hubs
#28 (p. 29): front disk and caliper
#320: front brake line brackets
#331: front disk brake covers
#346: rear brake disassembly, lubrication, new dust covers
#355: assembling rear hubs with new seals and brake linings
#356: modified brake bleeders
#358: reassembly of front hubs and brakes
#363: brake lines
Parking brake #7 (p. 14/455): parking brake handle
#10: description of stock arrangement
#52: as bought
#54: as bought
#56: originality of mount
#134: handle
#146: handle
#186: complete assembly
#349: hand brake cables and ferrules
#351: parking brake mechanism and restoration
#352: parking brake parts source
#380: handbrake reconstruction and fitting
#384: parking brake finalization and mounting
Bumpers
#211: rear bumper brackets
#134 (p. 170-171): bumpers
#362: old and new over riders and brackets
#363 over rider mounting
Cabin
Dashboard #59 (p. 63): dash etc (RH drive)
#136-139 (p. 177-186): LH drive dashboard
#141 (p.191-194): dash binnacle
#153-156 (p. 201-213): dash
#158-166 (p. 221-238): dash
#291: aluminum dash
#358: dashboard reconstruction including instruments and glove box
#367 new dashboard
#403: rear view mirror rebuild and mounting
#411: dash control installation
#422-423: leather covering dash
Footboxes #28: RH drive footboxes
#59 (p. 63): footboxes (RH drive)
#153-156 (p. 201-213): footbox modifications for 289
#158-166 (p. 221-238): footbox modifications
#171-172 (p. 246-252): footboxes
#181 (p. 255-261): footbox modifications for clutch lever
#197 (p. 288): footboxes
#303: foot boxes for a Ford Zephyr 6
Interior #2 p. 1: left side in front of cabin
#25 p. 19/455: cabin overhead light
#152 (p. 199-200): cabin light
#367: new transmission tunnel and cabin floor
#369: old and new interior panels compared
#422-423: covering door cards, glove box
#423: carpets
#423: seats and seat mounts
#423: threshold covers
Parking brake: See brakes above
Pedal Box #59: pedals
#96 (p. 112-113): pedal box
#171-172 (p. 246-252): pedal box
#172: gas pedal
#186: throttle pedal bracket finished
#322: pedal box fitting
#323: pedal box construction & fitting
#328: pedal box powder coating and assembly
#363: accelerator pedal and linkage
#364: footbox installation including hydraulic cylinders
Rear View Mirror #169 (p. 240-243): rear view mirror
#423: exterior drivers side mirror
Seats #33 (p. 32-35): seats
#71 (p. 73): seats
#108 (p. 124): seat redo
#292: seat runners
#368: seats and tracks
Seat Belts #281: seat belt anchor brackets
#294: shoulder belt brackets
Carburetor
#124: converting Holley Street Avenger to manual choke
#411-412: carburetors, linkages, manifolds, and air cleaners
Differential
#62 (p. 63-66): rear frame and differential, ENV vs Jaguar differentials
#68: weights
#73: brackets
#82 (p. 88-96): Jaguar differential mounting brackets
#89: differential brackets
#91 (p. 99-105): Jaguar differential mounting
#93-94: differential mounting
#120 (p. 140-151): differential, drive shaft, transmission mounts
#122: differential mounts
#139-141 (p. 187-190): upper differential bracket
#168 (p. 239-240): differential rebuild
#171 (p. 243-245): differential rebuild
#186: finished brackets
#190-191 (p. 277): differential gears and ratios
#320: ENV differential for Zephyr
#340: differential cleanup and reassembly
#342: differential seal fabrication
#374: differential installation
Doors
#3: as bought inner right side door
#127 (p. 157-158): door fixes
#232-233 (p. 385-393): door fitting, hinges
#245: door sill fabrication and replacement
#254 (p. 429-455): door rebuilding, fitting, and car VIN stamped in door
#256-267: door rebuilding and fitting
#264: window frames
#271: front quarter window latches
#273: adjustable door brace and door fitting adjustment
#280: door frame and inside panels
#303: doors and window frame mounts
#303: front quarter windows
#387: door panels and structure
#403: door handles
#423: door cards
#423: door installation
#423: door locks
#423: door windows
#423: rear quarter windows
Drive Shafts
#78: (p. 83): drive shafts (MkIV, new Aceca, original Aceca)
#84-85: half shaft sources
#120: Kirkham driveshaft
#312: Zephyr drive shaft
Exhaust
#319: exhaust routing through floor outriggers (Zephyr)
#322: muffler and exhaust pipe fitting (Zephyr and all others)
#325: muffler brackets (Zephyr)
#326: exhaust header construction
#348: heat wrapping exhaust manifolds
#350: header gasket fabrication
#392: exhaust pipe routing and hangers
#412, 414-417: exhaust pipe wrapping
#418-421: Lambda sensor, air/fuel monitor (see also instruments)
Frame
#5 wood repair using epoxy
#56: alloy body nailed to framing
#28 (p. 27-28): engine compartment looking fwd and backwards
#46 (p. 47-48): rear framing & B pillars
#52 (p. 50-52): frame and rockers
#55 (p. 53-58): rear framing
#57 (p. 59): front framing
#57: frame rust prevention
#59: looking back at rear frame from between doors
#62 (p. 63-66): rear frame and differential mounts
#112-113: determining strength of main frame tubes
#181 (p. 261-267): borescope examination of inside frame tubes and discussion of strengthening needs
#182-185: frame strength discussions
#197-202 (p. 288-309): frame strength analysis and reinforcing tube insertion
#199: old reinforcement tube for differential mounts
#203: front subframe
#204-205 (p. 318-321): closing frame holes
#206-207 (p. 322-325): rocker repairs
#208: upper rear shock mounts
#211-213 (p. 334-338): rear frame repairs and how to do them
#208 (p. 326-331): rear frame (behind seats) repairs
#217 (p. 347-348): bracket for spare wheel fixing rod
#221: alignment discussion
#222: closing main frame tubes
#222-224: sill frame reconstruction
#225 (p.366-369): frame repairs behind seats
#226 (p. 370): seat runner supports
#226 (p. 370-372): B column brace
#227: rear subframe
#218 (p. 349): rear subframe complete
#227 (p. 372-374): rear subframe installation
#293: brackets to attached panel behind seats
#315: door jamb A pillar panels
#316: right side rocker repairs
#317: front frame exposed
#319: rebuilding front frame
#327: framing reconstruction at bottom of A pillars
#333: door jamb A pillar panels
#334: JOKE about stripped frame
#335: painted frame
#336-337: frame coating
#367: rear bulkhead and framing
Fuel Pump
#374: installation and mounting
#392: mounts and fuel filter
#396-397: fuel pump plumbing
Fuel Tank
#25 (p. 22): fuel tank mounting and rear frame
#36 (p. 36): fuel tank internal plumbing
#219: interference with A arm brackets
#219-221 (p. 350): fitting fuel tank, repairing frame to suit.
#246 (p. 404-405): fuel tank straps
#294: installed
#322: modifying fuel tank for Zephyr
#390: fuel tank construction and testing
#392: fuel level sender and fuel line
#392: old and new tanks compared
#392: fuel filler cover
#393-394: fuel tank construction
Gearbox and Clutch
#12: Ford 289 V8 and toploader
#96: toploader in car
#120: gearbox with drive shaft
#120: half shafts
#122: gearbox bracket
#133: gearbox etc in car
#295: Zephyr gearbox
#299: Ford Type 9 gearbox
#299: clutch and flywheel
#300: Zephyr and gearbox
#300: fitting gearbox to frame and footboxes
#309: bell housing for Ford Type 9
#363: clutch hydraulic lines
#378-379: gearbox shortening
#380: shift lever and knob
#385: gearbox fitting comments
#387: right angle speedometer drive construction
Grease Gun
#279: R&R
#403: grease gun mounts
Hatch
#127: as bought
#128 (p. 158): hatch
#248-249 (p. 410-414): hatch window and fitting
#252-253 (p. 423-429): hatch R&R
#253: hatch lock mount
#368: hatch installation and shimming
#403: handle, latch, and badge
#412: struts and modifications
#417: leather work on hatch window edge
#417: hatch mounting and hinges
Headers
For 289 #127: header on motor
#133: new headers
#133: mounting motor with headers
#134: header problem with motor mount
#157 (p. 216-220): making headers
For Zephyr #326: header construction
Heater & Ventilation
#69 (p. 70-71): MGA heater and duct
#129 (p. 164): heater vents
#172 (p. 252-253): foot box air vents
#186: ducts
#323: original heating system ducts
#324: heater fitting and mounts (for Zephyr)
#324: ducts
#328: heater ducts and addition of heater ducts to Smiths heater
#365: heater, heater ducts and vents
#366: demister and heater installations
#371, 411: heater and heater hoses installed
#374: R side heater and vent hose arrangement, mounting bracket
#402: ventilation hoses and mounts
#411: heater valve, mounts, and associated hoses
Project History
#400-401: progress
Horns
#89 (p. 97): horns
#368: horn switch
Hubs
#344: front and rear axle disassembly
#345: rear hub problems
#348: hubs, spindles, and uprights back from painter
Lights
#37: tail lights
#358: headlight alignment
#423: driving lights
Instruments
#7: speedometer drive
#60-61: speedometer cable discussion
#125: speedometer cable discussion
#142-145: speedometer and tachometer mounting in binnacle
#384: instrument panel construction
#412: speedometer cable fabrication and connection
#418-421: Lambda sensor, air/fuel monitor
Motors
#12 (p. 13/455): Ford 289 and toploader
#28: 289 vs Daimler V8
#29-31: comparing motor weights
Carburetor #124: converting Holley Street Avenger to manual choke
Zephyr #295: Ford Zephyr Mk II motor and gearbox
#295: stripping block
#296: stripping head
#297: flywheel, friction plate, clutch cover
#300: Zephyr motor and gearbox much longer and narrower than 289 and toploader
#300-302: fitting Zephyr in car
#306: Zephyr connecting rods
#307: valve gear, water pump, oil filter
#308: assembling intake and carburetors
#308: fitting in car
#311: distributor and ignition system
#312: accessory brackets, oil pan, oil temp sensor, engine mounts, drive shaft
#312: starter
#371: motor installed
#376: increased displacement possibilities
#382-383: flywheel cover, crankshaft
Motor and Gearbox Mounts
#94 (p. 105-110): mounting 289 and toploader
#97 (p. 113-119): engine mounts
#120: motor mount
#133 (p. 169-170): frame modifications to fit motor and gearbox
#133: mounting motor and transmission in car
#134 (p. 172-173): motor mounts
#178 (p. 254-255): transverse brace for preventing engine mount rotation (note that mounts are clamped, not welded, to the frame to make motor change possible)
#194 (p. 281-286): improved engine mounts
#202-204 (p. 312-317): another improved engine mount to brace frame alignment
#228-229 (p. 375-380): improved engine mounts
#229-230: drive shaft safety loop
#309: Ford Type 9 gearbox fitting
#384: gearbox fitting and mounting
#398: motor installation
#398: engine mounts and modifications
Radiator
#28: radiator and fan
#314: radiator
#407: dimple dies
#407-410: expansion tank mounting and discussion
Cooling Fan #314: cooling fan
Replating
#151-152 various parts before and after
Reservoirs
#132 (p. 167): clutch and brake fluid reservoirs
#403: clutch and brake reservoirs mounted
... to continue ...
What do I do with the Aceca? Well, I try to get it on the road. For that I had a lot of small jobs. Today, I installed a hazard switch. Not so easy to detect the right wires for the brake light switch and the flasher can in an unknown wire loom. Both must be disconnected from the ignition and must be connected to the hazyrd switch so that in the case of switched on ignition, switched on hazard switch and pushing the brake the hazard switch has the highest priority.