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4wheeledstool

Cavalier mk2 - another blue giffermobile.

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The worst of the muck is now off. 

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Just need to convince a neighbour to let me have a go of his steam cleaning rig to finish fhe job off! 

This thread may go a bit quiet for a while now, as my freshly painted scooter bodywork will be arriving soon.  :)

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Managed a cheeky couple of hours on this on the way home today. Got a third and final coat of epoxy mastic on the underside. 

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Just a good layer of stone chip away from being finished under here now. Once everything topside has been painted, the underside will get a coat of underbody wax before reassembly commences. :)

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Another week where time is in short supply, but stuff is happening. The back of the horn was very rusty, but still worked well. Its bracketry as well as the gearbox mounting bracket will be sand blasted at work at some point. 

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After one application of the Deox gel, the back of the horn looks like this. 

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Should be good enough to paint after a few more applications.  :)

Made a start on the inside of the nearside front wing, and a little hole appeared in one of the pitted patches. This will be welded up and dressed back before it gets treated with the Hydrate 80.

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I'll hopefully get it all stripped and treated at the weekend. 

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Welded up the little hole that appeared after hitting one of the pitted areas with the wire wheel. 

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Whilst the welding gear was out, I replaced about an inch of the turned over section of the top of the wing - it had gotten a bit thin due to corrosion. 

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Once all the wax had been removed, the rest of the paint and sealant was buzzed off. 

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After giving it all a good rub with some 80 grit, then a good clean with thinners and white cloths. 

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The dark areas at the lower front end are where the metal is pitted - pretty much where the original wings rotted out. 

Engine/gearbox mounting brackets cleaned up well after bead blasting, I'll be painting these silver at some point. 

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Hopefully more tomorrow.  :)

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Horn is looking better after another application of the Deox gel. 

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Engine mounting brackets painted with engine enamel. 

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Nearside front wing Treated with the Hydrate 80. These will be getting epoxy mastic + stone chip same as the underside. 

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Offside wing before wax removal. 

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And after. 

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Obviously this will be stripped back to metal and treated same as t'other side.  :)

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I found out that I'm being made redundant earlier this week, so there's upheaval to come. My fingers are crossed that it all works out, but in the mean time, on with the show!

The offside wing is now just a good clean away from being hit with the Hydrate 80. 

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The nearside wing has received some seam sealer to replace that which was removed. 

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In other news, the rusty horn isn't far from being rust free now - one more application should see it ready to paint.    :)

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On 10/31/2019 at 8:34 PM, danthecapriman said:

Sorry to hear your being made redundant. Maybe you could consider a career in restoring rusty Vauxhall’s!

But what would I do at weekends? Anything and everything is being considered! 

On 10/31/2019 at 9:43 PM, Cavcraft said:

What a pisser about your job, fingers crossed you find another ASAP.

I'm sure I'll be able to find something, the big worry is that I'm gonna have to be incredibly lucky to find something that pays anything remotely similar to what I've been getting. I'm reasonably confident that I won't have to sell all my crap - I'm lucky in that is my biggest concern. 

Drivers side wing now Treated with Hydrate 80, and seam sealed. 

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The gearbox and its mountings are now ready to be stashed away until the time to reassemble comes. 

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Finished up the session by making a start on the engine - coolant pipes, alternator, starter motor and exhaust manifold came off before I escaped into the darkness that is teatime.  :)

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Got a bit more stripped down this afternoon. Cam belt covers, belt, sprockets and water pump followed by the thermostat housing. 

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Annoyingly, one of the little bolts that hold the thermostat cover down cracked the lug that contains the threads when I wound it out. Hopefully a mate can repair it for me with his TIG set, if not I'll be trying to find another housing. Part no. 90220434 88-1 :(

The lower outer part of the cam belt cover is missing, as well as several of its metal clips. The "wanted" list begins! 

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Also required - 

Cam belt,

Water pump

Gasket set 

Thermostat

Crankshaft pulse sensor

All for 1.8 SE. Any help sourcing these bits would be most appreciated. 

 

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A little more done today - the insides of the wings received a coat of epoxy mastic. 

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Back to the engine, first up all the wiring was removed 

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Then the inlet manifold came off. 

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This leaves me with a large amount of cleaning to get through, but due to a weekend away, it won't be getting done for a while! 

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Seriously cold/damp grimness this afternoon, but still managed to beat the urge to go home. Lots of messy clean ups to do, so I decided to let myself in gently with the starter motor and alternator bracket. 

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The starter motor will be painted satin black, and the alternator bracket will be getting a rub with a scotch pad to brighten it up a bit. 

After ignoring it for a fair while, the horn is now ready to paint. 

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A cambelt, water pump, thermostat and gasket set are now on their way, and a mate has given me a crank pulse sensor. It's from  mk3 cavalier - it's plastic instead of metal, but fits the hole, and the plug is the same. I don't know if this will work - if anyone can advise me on this, I'd be most appreciative. :)

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Mk3 one on the left. 

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Sorry to hear about your redundancy. It happened to me earlier in the year.  I was able to find another job in the same field, but as you say at a lot less money. I hope every thing goes well for you. with your skills, I would think you would be able to set up your own business restoring car.

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I think distance from the flywheel is critical for crank sensors so wouldn't think that will work, not sure where you are specifically in Cheshire but there's at least 2 cavs of your vintage at A T Wades salvage in Winwick , both likely destroyed bodily but may yield other bits for you

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15 hours ago, omegod said:

I think distance from the flywheel is critical for crank sensors so wouldn't think that will work, not sure where you are specifically in Cheshire but there's at least 2 cavs of your vintage at A T Wades salvage in Winwick , both likely destroyed bodily but may yield other bits for you

A serial mk2 botherer on mk2cav.com reckons the metal + plastic ones are interchangeable, so I'll definitely be giving it a go. (all the replacement ones I've seen on ebay are plastic too) 

Wade's isn't far from my gaff, I may well go and have a look on Saturday. :)

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Procrastination took up most of the available time today. I did manage to get the alternator cleaned up though. 

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I'll be blasting and painting the fan, pulley and tensioner arm in the week to smarten them up a bit - the main body came up well enough to leave as is.  :)

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More cleaning done over the last couple of days - first was the engine wiring loom. 

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Never knew that the injector plugs were yellow until now!

All the coolant hoses and hard pipe were then dismantled and given a thorough cleaning, they came up surprisingly well. I need to swap out a few corroded jubilee clips before they go back into service, the pipes were then reassembled so I don't forget how they go. 

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The starter motor was then given a couple of coats of engine enamel. I'll be using the same stuff on the engine block when I get round to cleaning all the crap off it. 

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More cleany/painty stuff to follow!  :)

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Finally got some paint on the horn. As you'd expect after being so rusted, it's severely pitted - but does look a lot better than it did. 

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The alternator bits have been blasted, painted and put back together. Looks pretty reasonable now. 

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Made a start on the inlet manifold + associated gubbins. 

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Got it all stripped down, now just need to pretty it up a bit. :)

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Finished cleaning, then reassembled the inlet manifold stuff. It looks a bit nicer than it did last week! 

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I also got the cam belt covers cleaned up ready to put back on - still on the hunt for the missing lower outer part. 

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I had a bit of a trial with petrol/diesel mix for cleaning the head/block. Its no better than neat petrol, but there's a free supply of it available to me at the moment. 

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Before I left, I cobbled up a blanking plate to stop crud falling into the engine now the dipstick/breather has been removed. There's gonna be a fair bit of muck flying about when I get stuck in to cleaning this thing! 

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Made a little progress with cleaning up the lump this afternoon. 

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The plan is to get the top end satisfactorily clean and leave it as bare alloy. The bottom end will be done in black engine enamel. (still a long way to go until its all clean enough)  :(

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Time has been in short supply again this week, but I've still managed to get a few bits done. 

Made a start bare metalling the block. 

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Smartened up the HT lead clips that bolt to the camshaft cover. 

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Breather pipe/dipstick tube, its bracket to the block as well as the dipstick itself have now been blasted and painted up. 

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In other news, I spotted another new wheel trim on ebay, having a spare one can only be a good thing. :)

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All oil + paint now removed from the block. 

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Just needs the rust wire wheeling back to shiny metal and it can be painted. Probably gonna have to leave that until it warms up a bit though - far too cold to paint anything in there at the present time. :(

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Not had any time for this until this afternoon. The core plug that sits behind the starter motor looked a little suspect after I took the wire brush drill attachment to it. It was rust pitted much worse than the others, so it was ousted. 

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A full set was procured from ebay 

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And the dodgy one was replaced. 

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Hopefully I'll get this painted at the weekend. 

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