BE 646

[dkp_cobra]

Daddy got a new toy: a strecher/shrinker from far east. Although it is a quite cheap part it works.
   
   
   
   This tool should help to make new panels for the boot. The old panels are scrap.
   
   
   
   The stretcher/shrinker is necessary for the bending of the upright panel:
   
   
   
   Here is the result:
   
   
   
   
   
   
   
   The new panel has the same size as the old one
   
   
   
   although the curve is a little bit wide
   
   
   
   But it fits the new lower panel:
   
   
   
   Well, I am satisfy especially when I think about my skills bending metal at the beginning of the project [xx(]
   
   

[nikbj68]

Wow. Superb craftsmanship!

[bobbylangley]

This car will be better than it ever was leaving the factory, hats off to you and your skills.

[dkp_cobra]

Checking whether the panels also fit inside the car.
   
   
   
   Enough space for the spare wheel:
   
   

[Wolfy]

Great work, great updates.

[dkp_cobra]

I am still working on the boot panels.

It's always quite exciting when you worked for a quite long time making a panel and you have to drill a big fat hole into it.



If you don't know the exact place and if it doesn't fit perfectly, your only choice is to make it even bigger. This has happened in the past with the original panel. Maybe due to the fact that the new patrol tank has the filler at a different place or has a difference angle.



But I think I managed it this time with my first try.

[dkp_cobra]

My definition of "attention to details": "solving problems which don't really exist with a huge amount of energy".

The rear upper panel of the boot was riveted to a cross tube. In the past this cross tube was rotted from inside to outside because water entered this tube by the rivets. So I hope that my brackets will prevent this.





And from the backside. There are also the holes for the rivets fixing the GRP driver cabin back wall.

[dkp_cobra]

Before christmas I started with the overhauling of the seat runners. I guess that power coating wouldn't hold out for a quite long time so I tried something new: black zinc-coating



and for the handles just a normal re-chroming

[dkp_cobra]

And some more brackets



to fix the wall behind the seats

[dkp_cobra]

I think the new boot panels are finished. Here are the old ones:




and the new panels



and installed in the boot







New brackets for the safety belts

[dkp_cobra]

I'am back. The intermediate project is nearly finished and I plan to do more on this car again. To make this project a little bit more complex I bought a new engine two weeks before.





Yes, it is a complete but quite rusty Ford Zephyr MK II inline six (206E) engine. Unfortunately, it didn't turn. That's not a good sign but hey there are not so many Ford Zephyrs here in Germany. You have to take what you get.

Opening the valve cover was quite promising on the first look.





But after removing the head the horror began.





All pistons were stucked. I could remove four of them without problems. The one which looked so bad could be removed with some more force. The pistons which looked best made the most problems. While removing it the cylinder sleeve came out.





After that I could separate the piston from the liner.



I believe the main problem of the engine was a bad service. I guess no one made an oil change but just refilled oil when the engine had to less. In the oil sump was oil mud and the oil filter of the oil pump was opaque.





Now I am looking for spare parts and/or an expert who can rebuild the engine. Any advice?

[dkp_cobra]

Disassembling the head. Most of the rockers were stucked.






Two valves were heavily trapped that only a 12 ton press removed them.







But I think the head can be restored.

[taffe9]

Gosh those engine pics. look a bit grim! I have the remains of a couple 206e engines around the workshop after a number of Aceca projects & a few new spares in boxes eg a new old stock set of conrods, oil filter adaptor for canister filters etc. Let me know if I can help.
The engine itself is very basic in design & judging by the quality of the work you have achieved so far you should have no problem rebuilding one yourself.
Regards

[dkp_cobra]

Hi taffe9,

did you get my pm? I am quite interested in the spare parts you have.

Kind regards,

Peter

[dkp_cobra]

The old flywheel, friction plate and clutch cover.



The previous owner didn't change the friction plate when the time was right for the job. The result was a bare friction plate and deep rills in the pressure plate.



After cleaning the flywheel it looks quite promising.





The new friction plate



and the new old stock clutch cover



Checking whether the gear box will work with the friction plate and the engine. It's a Ford Type 9 gear box. This is quite cheap, has five gears and the best Quaife produces a heavy duty version of this. One can never know whether this will be necessary  .



Oh no, a modern five speed gear box! Yes, a little bit hot rodding must be allowed. It was a far way for me to drop the V8 plan ...