A sort of barn find

[Matthew Barnes]

Originally Posted by icarp

Wow what great work . I love it . Just a thought about your MFI screens , they can knock off as much as 30% of your horse power , The world of racing stopped using that type of protector back in the mid 60's because of what it did to the horsepower .
I love what you are doing . Just adding a little info
Ian

Thanks Ian.
Now that's interesting. That's a lot of HP to lose.
Explains why the likes of the early McClaren etc had no covers on the stacks.
I think you are right - might be best to stick with the original air-cleaning system.
I am aiming for this car to be a 'go' car and not just a 'show' car.
Stay tuned.
Paint is almost cut and polished - and then the fun bit really starts: trying to put it all back together!
Cheers.

[Matthew Barnes]

The visors have gone through a few iterations.

I tried to use Balsa, green acetate (ala Fear and Loathing in Las Vegas) and most recently, metal mesh.





Nice, but no.

Next one: using some old leather from a rubbish seat I inherited with the project.








The leather handles are from a firewood basket that couldn't take the stresses of life in winter. Everything has a use, even when it is useless!

[icarp]

Your finished sun visor looks great!
Keep at it . I love the fact that you plan to drive it !
I put 30,000 miles on my RS clone in the first 18 months of ownership
ian

[Matthew Barnes]

Thanks Ian.
That's a lot of mileage.
Brilliant.
I hope to do something similar when the LO is alive.
Matthew

[Matthew Barnes]

A lot has changed since I last uploaded.
Looking back over the last year is a sobering experience.
Hope all of you Pelicaners are good.

I've made some progress.

Cutting and polishing.
These Trizact pads and Farecla Compounds are amazing.

[Matthew Barnes]

Assembled the stacks with all repeated bits.
Very impressed that the plater didn't lose any of the bits.

[Matthew Barnes]

Brake reservoir.
Very scared of having this vital piece of kit hidden away where it can't be easily seen.
May need to be adjusted but fits well with two steel lines running down through the Smuggler's box.

[Matthew Barnes]

Got the brakes all installed.
The callipers gave me a few headaches.
I couldn't understand why the pistons wouldn't seat properly.
I searched high and low for a solution.
Nothing.
The solve was to strip the callipers and to thoroughly clean the guide.
They looked clean, but alcohol and compressed air pushed a huge amount of much out of the springs.
And presto, once I had done this, the buggers slid on with ease.

The upside is that I can now strip a calliper, clean it and reinstall seals in under 5 minutes!

[Matthew Barnes]

The handbrake mechanisms killed my thumbs.
Despite some seriously professional blue language and repeated attempts, I just couldn't get the springs and pads to sit in position.
Will have to think a bit more about this tricky job.

[Matthew Barnes]

Washer bottle.
Built from the parts bin:
An IB washer bottle, upside down.
A 928 pump
Some alu sheet.
And some epoxy.

[Matthew Barnes]

Glove box and dash.
Not sure why, but an alu glovebox door seemed like a good idea.
And of course, then the dash face.
I really need to get a decent bending brake.
Fascinating metal is alu.
I have huge respect for the pros that work and shape this stuff.

[Matthew Barnes]

Having some fun with the set of stamps I bought.

[Matthew Barnes]

I have been dreading these buggers.
Seized and snapped exhaust studs.
I finally gathered up the bravery, and a rather clever guide tool from Stomski.

The first took 8 hours.
The last 10 minutes.
Sharp drill bits and a long shank tap.

Hope I didn't ruin the heads....

[Matthew Barnes]

All new gaskets, nuts and washers on the covers.
Engine tin beaten back into submission and repaired.

Nice to find an old sticker on the engine oil cooler.

[Matthew Barnes]

Cleaning up and wrapping the harness.
Amazing condition considering it's original to a '67 car.











I've never done any wiring before. So figuring out a wiring diagram has been a learning curve. Huge help from the various Pelican threads. A whole bunch of fuses died in the pursuit of working tail lights and indicators.

[chrisbalich]

That's a helluva update!

Keep going!

[Matthew Barnes]

Fuse box for the front and sorting out the rear panel.
Patching an MFI harness into a '67 harness has been interesting.
The fact that some parts are NLA makes it a real head scratcher.

[Matthew Barnes]

Still trying to decide on wheels.
Steelies or Fuchs.
I have managed to gather together 4 Fuchs all date stamped '67.
Not sure.
The steelies are equally gorgeous in my opinion.
We'll see.
Satin black whatever the choice.

[Bear911]

Nice update Matthew! I'm going to invite myself and drive through to you as soon as we no longer have to dodge viruses! I need to see this in person.

Just went through the business of wiring up a car myself. It's daunting but ultimately super rewarding! Keep it up, it will all work out in the end!

[Flojo]

I really like how this one is coming together.
Attention to detail is at level with the very individual sports purpose design.

regarding wheels: I'd use the fuchs with a sporty tire and the steelies with a rougher taller tire for some Offroad/winter use.