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Secret Project Finished


Kevin Abbott
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It started like this.

" Carl, can I come and buy the roof off you as a spare?"

 

That was Friday 20th March 2015

 

Sooooo, over to Burnley we go, 10 mins away.

Picked up the roof as a spare for my #itsnevergoingtobedoneinamillionyears project

 

Out of the corner of my eye I spied this 

 

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Rusty? Hell yea

 

 

 

Balls to this, this forum is a pain in the arse to build a thread

I'll do it on facebook

Edited by Kevin Abbott
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Ok, I've put my dummy back in......

 

The plan with it was simple, Danny the boy  Danny D114BCW was in Europe doing a tour and his car went to the bodyshop

 

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For a little bit of paint..

 

Danny thought I would never have a car on the road so this was my challenge....

 

I had 3 weeks to fully restore and paint the coupe.. 3 weeks :lol:  My other coupe I have been building for 14 years

 

Did I mention it was rusty? well not as rusty as some as it still had a floor and good 'A' posts. A glass sunroof was a saviour and the headlining was good and in black. The interior was cut about for a mega bosh boom bang stereo with 6x9 speakers in the doors... who does that! especially to early 400 style door cards :blink:

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To be fair it has rot in the standard manta places but it's got some nice bits on and needed saving

 

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Yes it is a 1800! 

 

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Time to strip it :ph34r:

 

 

 

 

 

 

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Found one nearly identical on Monday white 18S coupe wrong seats, steering wheel and backbox had a quick wiz round it and needs attention to the usual places and the owners keeping it to fit a BMW 6 cylinder diesel in :(

I tried to buy it but it wasn't for sale so left my number with the guy :( :(

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First thing to do was make sure the car was running OK before we took it apart and it was 
 
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Then onto the lorry lifts to have a poke around under it again and to release the running gear, exhaust etc 
 
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Sticky black stuff removed and cleaned with thinners, floor looks good but I haven't hit it yet:)
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A little investigation into the front end resulted in replacing the top section and a bit on the grill

 

 

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Then ground back347_zpsw5iuuve1.jpg

 

Back to bare metal to find the worm

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Now I knew the chassis was bad but I needed to put it on the body turner my brother had bought for his Mancona off Mantasport. Assessing the sills the pass one required 1/2 a sill with all closing panels repaired and the drivers one I put a full sill on and did the repairs to the inners behind the outer closing panels on the rear quarters

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Borrowed my Brothers HEAVY spot welder :blink:  and a day of messing around to get the sill lined up correctly

 

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Both A post required repair so my shrinker/ stretcher came into play.

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Shell was now strong enough to go onto the turner but before we could do that it was all axles and heavy things off

 

 

 

 

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Spare wheel well needed replacing so I made one 

 

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With the shell strong it was time to do 

 

Drum roll...................................................

 

THE CHASSIS LEGS

 

ARRRRGGGGGGHHHHHHHHHHHH

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onto the lorry lifts

put it on the body turner

Borrowed my Brothers HEAVY spot welder

so my shrinker/ stretcher came into play.

 

 BLOODY CHEATS !!!!!!!!!!

 

 You should be rolling around on your back on the front drive, rain dripping down your neck, fighting with a cheap e-bay mig and set of old hammers !!!!!!!!!!

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 BLOODY CHEATS !!!!!!!!!!

 

 You should be rolling around on your back on the front drive, rain dripping down your neck, fighting with a cheap e-bay mig and set of old hammers !!!!!!!!!!

I'm very lucky Ian that my little Brother owns 4 large industrial units and employs a painter

More of the thread to come day by day.

It's going to be some story

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The chassis legs

 

On the advice of David from Mantasport I did then one side at a time

 

Poke the old chassis until it is dust and cut out the rot

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New chassis rail pieces by Klokkerholm ordered from

http://www.tjmotorsport.co.uk/

 

The service from TJM was fantastic and they gave me a 10% discount for being in the club ( I'm not pregnant :lol: )

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TJM didn't have all the parts in stock to send the next day to suit my schedule so Big Cliff came to the rescue with a full set of klockkerholm chassis pieces.

Many thanks to Cliff Hill, now then that was another person let into the secret project and news was getting out! 

 

The old rusty parts cut off to leave this 

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Inner built from 40mm box bent to suit 

 

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Inner all welded up and zinc primed

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Blood sacrifice

 

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Now the outer was added, the panels fit so well with a little squeeze

 

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New jacking point on this side too

 

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Zinc primed and off to the other side

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So I put over 100 hours welding into the chassis going from work every day

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This is how you look every night at 2am after doing chassis rails

 

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At least the shell is now strong.

Just a inner rear arch to add

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Edited by Kevin Abbott
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Amazing application to the task, credit to you, makes me feel a right lazy mutha, mine is up in the air waiting for me to get the fuel tank out.

 

Andy..... (Rutts) where are you?  Need a grunter to lie underneath the car with me, and not the wife.

Edited by plumster
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Time to move it

All the welding completed in a crazy 3 week timeframe.

Well, I had wanted to complete the car in 3 weeks to show Dan, I rang Dan as he was on the way back from daaaarrrrrnnnn sssaaaaaauuuuthhhh dropping off the motorhome and asked him to call and look at my coupe project.

He arrived and did this

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" What's happened to your coupe? I didn't know it needed that much work?"

 

Then he looked and looked. The more he looked the more nothing happened :wacko:

 

Then the penny dropped

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"THAT's not your car!)

 

Hmmmm Dan, yes it is but not the cossie project.

You should of seen Dans face light up.

Back to buissnesss and now with another person in the loop.

Dan called down the day after and I had more hands on the job .

 

Time to get the car off the body roller and move the car next door into the prep bay

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Easy with a stacker

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onto a body roller

 

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Into the paint bay and back onto the body turner to prep the underside for bedliner

 

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Dan doing the masking. The entire underside had been cleaned back to rust free and treated with an industrial rust converter that's mainly used on oil rigs so should be ok for a rusty Manta

 

 

 

 

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Drying the rust converter

 

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Edges seam sealed

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Time for  ........................RAPTOR.... Grrrrrrrrr

 

 

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I bought the tintable version and added 2k black so it's nice and shiney 

 

While the raptor....... grrrrrr...... was going off Dan took it upon himself to use the industrial wash and a s##t load of TFR and acid to do some cleaning

 

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There is a lot of love for the Mantas around here

 

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With the raptor... grrrrrrr.... drying it was time to look at the drivetrain and axles

Axles cleaned and 2k

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Derusted and black 2k lashed on

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Flying axle

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Boot got a bit of 2k love

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Prop and exhaust cleaned and painted. no pics.... booooooo

All bolted onto a clean shell and back onto its wheels

Phew! It all lines up :lol:

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Time to strip it down for paint, but wait... what about the fuel lines and new brakes?

Over to the other bay again and up into the air. Big Cliff trying to bend down to do the lines on the highest setting of the lift :D

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Brand new death wish calipers sourced from brakes international

( won't have those on for long!!)

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At this point it's 4 or 5 weeks into the build and 100s of man hours but it's all worth it when you can sit in your Manta

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Edited by Kevin Abbott
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