Struth will this ever end !

The more we get into this car the more we find to laugh at, I don't want to sound patronising but some of the mistakes we have found have been really basic and some of these are actually Dangerous. The Electrical installation on this car was one particular example of multiple "Bodge ups" Take this for example this is how one of the cars previous 4 owners decided to joint 3 wires together ! Mind you it was wrapped in insulating tape so that must be OK then

This was how our "Amateur Electrician" Earthed part of a circuit Now like I say I do not want to Criticise another builders efforts but in our case some of the bodges have been unforgivable !

So out came the loom, we were quite pleased to find that it was a Vicky Green Loom, There have been some rather dubious reports about this loom but in our case we were happy, Imagine what a mess "Amateur Electrician" could have made to a complete Sierra Loom !!!

Here we see Joey with the VG loom stripped of its "Bodges", not a lot to it eh?

Now we have removed the pedal box and the foot panel in front of it, again this has been fitted with the flange bent forwards which means you get less foot room, our solution is to make a new plate which the flange points rearwards and also move it forward so it is just clear of the manifold. Talking of Manifolds we have ordered ourselves a new Stainless Steel 4 into 1 exhaust from Robin Hood, we are happy with our one and the twin pipe jobbie in this 2B does not look that exciting.
As fot the tunnel wall, we have removed all the "Rusty" bolts and moved it towards the gearbox and will gain a good 2 inches more just by doing this, now we have to fill all the redundant bolt holes . We will of course be rivetting the panels in their new positions using Jointing compound on all the mating surfaces to stop the corrosion.
We obviously will have to remove all the rust stains thay have developed on the floor area, hardly surprising when there was amongst other things a "Rusty Stanley Blade" wasting away between the Stainless floor and the Aluminium Kickplate panel

Lets jump towards the rear of the car, Its just as bad at that end . Look at this Stainless Steel Stoneguard which is nicely fitted using Aluminium rivets and not a hint of Jointing compound or sealant of any kind, If you think it could not get any worse then have a look at the inside of the wheel arch:

Has this person never heard about Rivet Grip lengths ?, Well in case you haven't either these ones are about a mile too long. When a rivet of the correct length is fitted it should form in a nice symetrical shape the stem should break close to the metal, These are just useless they will have very little strength and would probably very soon work themselves loose.

There is another rule when Rivetting and that involves Spacings and I think you can guess that there is something missing in these Rivets, namely Space between the bloody things.

This picture demonstrates another thing needed when using this or any other type of fastner, There is whats called "Edge Distance"
Now if you look at the 4 rivets in this picture, firstly the 3 on the left only just pass on the previous "Spacings" Rule
(Shame about the Huge dent they are sitting in), but look at that rivet on the right there should be some material between the rivet and the edge otherwise it has nothing to hold on to, try to aim for 8mm Minimum and you will be OK.

See this ! This is the type of metal that plumbers find fitted to Boilers, Storage Heaters and other Domestic Appliances.
Notice the "Keep Dry" symbol, thats because if you get this wet it will rot in about 15 minutes
This was used a lot when filling gaps between the floor and rear panels etc, Nothing involving water then!

Here we have removed the passengers side panel, this was also stuck on with crappy rivets and no form of Jointing compound. We were glad that we did remove it because there was about a million extra holes drilled in the chassis. Possibly they were drilled as a weight saving project! More likely it was a Builder who did not have much skill with a drill.

And here is the Drivers side, Joey has removed the Unpainted Steel Exhaust cover and look what its done!


I suppose we will be back with more soon!!!

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