Art's FC Sedan Build 2.0

[Longman]

First application of filler. I used Fibral fibreglass filler, as it is non-porous and was covering a lot of welds and will finish off with a skim of regular filler.

[Longman]

Every little step, is one step closer. Did one of those small niggling jobs this morning, one I've been putting off, but turned out to be a lot of fun. Someone previous fitted a speaker to the rear parcel shelf, old skool style, with a drill and hammer. I don't intend putting a speaker there, so needed to fill the hole.

[ardiesse]

Did you do a bit of a hot-shrink here and there after welding?

Rob

[Longman]

Did you do a bit of a hot-shrink here and there after welding?

Rob

No mate, not necessary.

[Longman]

Had a good Easter Monday. Got the underbody finished and coated in KBS rust seal, gloss black. Another milestone, and another item off the list.

[Errol62]

Nice job Art


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[GMHwagoon]

 what size can did you buy and how many coats did you get out of it on the under carriage

[Longman]

what size can did you buy and how many coats did you get out of it on the under carriage

Hi. I bought a 1 litre tin, 2x coats, still have enough to do inside. It really goes a long way.

[waynos]

good work!

[my8thholden]

good work mate ,yep ,can also praise that KBS gloss rust seal ,great product ,it also makes a great top coat ,..stay well Vern

[Errol62]

Hell that is good coverage out of one litre.


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[Longman]

Time for an update. I had to make a decision on steering column. I want to keep the camper bench seat, so wanted column shift auto. After some deliberation, I decided to go with a Toyota Prius column, with electric power steering.  All in all it would take 3 columns to get what I wanted, the Prius as the main column, a Toyota Tarago for the column shift mechanism and an original for the honeypot/indicators.  The Prius column is a good fit, we only had to fab a pile of mounts under the dash to provide the necessary support, but ensuring it can still collapse as needed.

Some of the parts used:





Here you can see the positioning of the electric steering motor:



shifter trial fit:



Added a spare dash panel to test fit and clearance:



Butchered the original column. Was surprised how easily the honeypot and indicators fit:



Installed front seat for a test fit of my body and get the column length right:



Happy times. Will finalise cable selector, intermediate shaft etc once motor/box are installed.

[Errol62]

Genius at work. I’m amazed you made this work with the stock indicators and wheel.


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[camxsmith]

Holy shit takes some balls and imagination to make that work. Awesome love it

[Longman]

small update. Just working on fiddly bits, getting the engine bay ready to bolt back on. All un-needed holes filled and smoothed, ready to drill more. Will paint underside and frames in KBS, epoxy the good bits that people see.

[Longman]

finished off the underside of the engine bay/sub-frame in KBS gloss black, Happy with the result, brushes on nice and thick and self levels to an even finish.

[Longman]

Installed the battery tray in the boot, thanks to Mallaby Sheetmetal, the mount is a great fit, easily manipulated to suit whatever position.  Tomorrow's job is to finish the cleaning the boot area, seam seal and KBS coat it.

[Longman]

Did the B pillar seatbelt bolt mounts. I bought a set of plates off ebay. A lot of people came in from the sides of the pillar, we decided to come in from the top. That way we could stay within the lip of the pillar, on the flat, drop it down, then seal it up. A bit of bog and you won't know.\

[Longman]

The final part of a big weekend. After 2 years of welding, grinding and stripping, finally got the shell into epoxy primer.  I'm using Rustbuster Custom Epoxy 421, goes on great, easy to sand, 80 year rust guarantee. We started the filler work. As you can imagine, after 60 years, this old paddock racer had it's share of dings and flat spots. The roof was surprisingly good, with only a few low spots. The rear quarters were a mess thanks to makeshift tubs done with a big hammer.  They have come up nice and straight for now, once doors are stripped and mounted, we will finalise the quarters properly.  These pics are after application of Evercoat Black Gold filler and a swipe with a Melomotive spline. They are not yet sanded.  For anyone contemplating doing their own bodywork, I cannot recommend the use of splines highly enough, they will reduce the amount of filler you use and the time required for sanding.  Grey looks so much cleaner than black.

[Longman]

Last job for Sunday. Engine bay in epoxy. Nice.