Project A Red Rebel Restoration - UPDATED: 14 months of (non)progress

[vulgalour]

That's remarkable, it really is.

[CreepingJesus]

Top work! Looking back over this, it's amazing how much top work has gone into it. I can see how little things like the wrinkles in the headlining might annoy, but stuff like the vinyl work isn't easy, and you've done it really well.

Also, I'd be like a kid in a sweetie shop with all those tasty engine bits! The ingenious ways, and trick bits and bobs people in 750MC racing have come up with over the decades, are always a delight to see. I know my self-discipline would be out of the window if I'd to build an engine from those parts boxes...

[garethj]

A brilliant job, as ever.

 

Paint finish is excellent, was that sprayed or rollered on? I did my fibreglass 1958 Peerless in Rustoleum and the finish was really good.

[coalnotdole]

The paint and the last coat of primer were sprayed, theres some polishing still to do and a few marks created during the carpet fitting to be touch up. Generally the paint finish is good and a bit better than we thought it was going to be.

 

If it was up to me I'd have gone for a slightly darker shade of red but at least its a decent period looking colour not too far off where we think the original colour would have been. At various points there were discussions on it being painted black or even beige but. I'm not sure I could get used to thinking of as anything other than the red rebel!

[trigger]

Wonderful!

[coalnotdole]

I Spent some time over the weekend assisting dave in fitting the doors to the rebel. It also meant I got to see some of the stuff that had been going on since the last time I saw the car, like the overcarpets and shiny chrome exhaust trim!

 

Door fitting can be an awkward process if you want to make a decent job of it and get the top, bottom and swage line all to look good!

 

Overcarpets:

 

 

New stainless air vents.

 

 

Boot carpet

 

 

Chrome exhaust trim.

 

 

Hinges have had new pins made in 8mm stainless bar as the old ones were found to be rusted through.

 

 

Door frames painted

 

 

Trial fitting a fixed quaterlight

 

 

Door frames go in,

 

 

Door frames had new drop glass felt fitted, the quaterlights were sealed with black polyurethane sealant which has been very effective on the Scimitar.

 

 

New Quaterlight base rubber, I can get hold of more of these but they are not cheap. pm me if interested.

 

 

With the frames in the winder mechanisms and door locks were reconnected,

 

 

We then fitted some new british made tex door mirrors . We have replaced the old style door mirrors because they were shit.

 

 

We were very pleased with the way the top frames fit, it took some time to get them right but is now probably a bit better than the standard achieved by reliant.

 

 

 

A few photos of My GTE and Dave's rebel, I'm hoping to get the Scimitar respayed by the same sprayer who did the rebel later this year.

 

 

 

 

These last couple of photos are a sneak peek at the new seats for the rebel which are currently being made .

 

 

 

The plan is to carry on and finish the cosmetic stuff on the rebel and then concentrate on getting the race engine sorted towards the end of the year

[Pete-M]

Ace. Every time you post about the stuff you've done on that little Rebel I feel slightly more inclined to do things to my stuff.

 

Can't wait to see the completed thing. Love the carpets, by the way. Look like they should be in a Jensen or summat.

[coalnotdole]

Ace. Every time you post about the stuff you've done on that little Rebel I feel slightly more inclined to do things to my stuff.

 

Can't wait to see the completed thing. Love the carpets, by the way. Look like they should be in a Jensen or summat.

 

Cheers pete, I'd quite like to own a Jensen at some point I keep hoping I'm going to find a barn find FF for bargain money but somehow it hasn't happened yet!

[vulgalour]

Just seats and wheels to go, on the cosmetic front? It's looking really super, and the cream on the seats should stop the interior looking like too much of a blood bath. Very impressive, this is how it should be done.

[coalnotdole]

Just seats and wheels to go, on the cosmetic front? It's looking really super, and the cream on the seats should stop the interior looking like too much of a blood bath. Very impressive, this is how it should be done.

 

I think its a case of the more you think about it the longer the jobs list gets:

 

seat covers,

Seat frames need repair and new feet made,

door seals and boot seal need ordering,

dash needs to come out for a sand down and a paint and a new top cover cutting,

door cards need making as do the rear armrests and sun visor,

Wheels need sanding down and painting new hubcaps need buying,

new mirror glass needed for the rear view mirror,

front door pulls need sourcing (think they are a ford part)

 

At one point I was very worried about the varying shades of red going on but I think we might just get away with it. Regarding the colours we've taken our lead from what was there the carpet was red to begin with! as were the seats.

[dollywobbler]

Just brilliant. That is all.

[HillmanImp]

That looks ace. Good work sir.

 

As much as I like seeing these sort of threads it does reminds me that I actually need to do some work on some of my cars.

[RedSparrow]

Amazing, as always.

[michiel]

Somehow I missed this whole thread... and now I'm lost for words. Brilliant stuff!

[Danblez]

Most impressive, I have really enjoyed following this. You have made it all look so effortless but I imagine it wasn't!

[coalnotdole]

Brief update on the Red Rebel,

 

Since I last posted about it The seats repaired and retrimmed by the trimmer at the boatyard where Dave works in keeping with their striking origonal colourscheme. They've come out really well and they are really very comfortable.

 

 

A new set of door cards were made at the same time as the seats. These use plastic backs rather than the original hardboard so they should be far more hard wearing. The door cards are waiting for the final fit which requires another order of weatherstrip! then the handles and trim can go back. If anyone has a decent set of red door pulls we'd very interested (believed to be the same as escort mk1 and Anglia.) There is also a new set of sunvisors to go in too!

 

 

The arm rests are a sightly different to the original spec as they are trimmed all the way round with edging.

 

 

From then Its passed into regular use with Dave using as his main car, it still has the 600cc engine fitted which is now getting a bit tired and is burning a lot of oil, there are suspicions about a rumbling big end and the solex carb has will only fuel it with the choke left on a bit . The gearbox has also developed a nasty wine in second suggesting it too will need attention in the not too distant future.

 

With this in mind I delivered a tidy Low mileage (less than 17k) 850 to the island at the end of last week. This is to act as a bit of a safety net if the 600cc engine finally quits. The 750cc race engine has taken longer to develop than we'd have liked and is currently waiting for some machining; the crank wants a polish and the whole setup needs rebalancing. Other exciting goodies supplied include a Stainless exhaust system and a rebuilt fully synchro gearbox which is going to be fitted with the early type tailshaft (retaining the gear stick position where it is at the moment.) all of which are there as future projects.

 

As a final activity while over on the island the saloon was fitted with a nice new accessory... a front anti roll bar! this was a bit experimental as we were unsure how much difference it would make or how well it would fit. Photo shows one of the mounts which had just been welded on.

 

 

 

The wishbones already have the mountings for the drop-links so they were a straightforward fit.

 

 

 

Shown here with the anti-rollbar in place

 

 

 

Closeup

 

 

The handling has been significantly improved, there is a substantial reduction in bodyroll particularly when cornering and it has given a real improvement in the handling through sharp bends and chicanes. The improvement is marked and I'll definitely be going for a similar setup for the van as soon as the budget allows. There is a slight downside which is about a 1" reduction in ground clearance, possibly something that can be mitigated on the later style chassis (like the van )

[Angrydicky]

Love that interior. Cracking job

[Jack_Harpers_Teeth]

Spotted you! (sort of):

 

[coalnotdole]

It's been ages since this thread was updated, mostly as its been on the road being used and enjoyed! Since I last updated it was involved in an accident (a mondeo owner decided to reverse into it) and its since been repaired, (done in house rather than left to insurance.) It's passed another MOT in september with one advisory for an oil leak!

The big changes are the wheels which have been widened! The standard 12" diameter wheels have gone from 3.5J all round to 5.5J at the rear and 4.5J on the fronts. This gives a benefit in grip and handling, as well as adding a subtle dish to the wheels which really increases their kerb appeal. The wider wheels have also been fitted with new Falken tyres, Since the photos were taken its also been treated to new shiny chrome hub caps.

The dash still needs to come out for a coat of paint and some new vinyl on the top. There are plans to send a number of bits off for chroming including the gear stick, dash heater vent surrounds, sun visor mounts, gear stick and handbrake surrounds. There's also a plan to re-introduce period Britax seatbelts (chromed, of course!)

Outside the front indicators have been swapped for clear glass lenses, (some rebels appear like this in the advertising material.) A new old stock rear bumper has been fitted! replacing a slightly pitted original. I'm still on the lookout for a perfect front bumper to match! (although most of the mondeo dent has now been removed) In the near future the grill is going to be fitted with a stainless mesh to help protect the radiator.

The engine is still the 600cc engine that was dropped in as a temporary measure and has coped with the unfair demands put on it far better than we ever thought it would! It has a tendency to burn oil though and what it doesnt burn it chucks out the crankcase breather at an alarming rate... It also returns a fairly shocking mid 20's mpg! The plan is still to drop in a tuned custom built race engine, which is in progress. This can't turn out to be any less fuel efficient even with the Dellorto FZD I'm planning on fitting!.

An order has just been placed for a set of fully adjustable Gaz shocks and springs which will hopefully further enhance the handling. 


As seen here in some recent photos:







Work on the front brake Disc conversion is almost finished - I've been working on a setup allowing disc brakes to be used with the original 12" road wheel diameter. A standard Spitfire setup has clearance issues as well as being the wrong PCD, after much thought (or speculation?) I've come up with a solution which should be more than adequate for a Rebel....

This is a unique setup utilizing machined Vauxhall Firenza Hubs with turned steel adapter rings to take re-drilled triumph Spitfire Discs running on modified Scimitar 5 - early5a stub axles attached to New old Stock Triumph Spitfire Vertical Links, Inner bearings are on a specially turned 316 stainless spacer on which the Lip type hub seal also runs. Calipers are Genuine Girling type 14's with new pistons and seals fitted with Mintex pads intended for an Austin Maxi!.
Whilst this might sound like a complex nightmare it should mean that future service parts (bearings, Discs, seals etc)will be readily available off the shelf with only the stub axles requiring turning down in a lathe, it also increases the front track width by 2" which combined with the wider wheels should make the car handle even better than at present.

This shows the Viva Hub attached to the Spitfire disc:


Rear view showing the adapter ring mounted inside the disc:


Spitfire Vertical link and dustshields:


Rebuilt Type14 Caliper:


Complete Assembly:






Another modification I've been working on is a fully synchro' Gearbox - The early semi-synchro rebel Gearbox is derived from the Regal  but has a much longer mainshaft and a tailshaft extension with remote gearchange mounted on top - This remote is a precise feeling short throw setup which gained much praise in period reviews (virtually always considered best in its class). Later 750cc Rebels have a fully synchro gearbox but lost the remote change, as well as having synchromesh on first/second this box also benefits from a higher ratio gearset and better parts availability (close ratio gear-sets are also available for this box!). I decided to build a gearbox based on the 750 box but having the benefits of the early boxes Remote Change, this is complicated somewhat as reverse is a longer throw on the later box as well as being in a different position.

Having decided to create the ultimate Rebel gearbox it stood to reason the antiquated carbon clutch release bearing setup should be engineered out - Later three wheelers use a Ford Fiesta/escort roller bearing clutch - although this was only made as a cable operated setup. I've decided on a hydraulically operated system as this will be smoother and more robust, this has required welding bushes into the bell-housing to take a vertical cross-shaft to mount the Ford bearing on.
All Rebels (and most 3 wheelers) are fitted with inertia starters - When starting from hot it inevitably takes two or three attempts before the engine fully catches as the inertia starter gets kicked out as soon as the engine try's to fire.

Very late three wheelers have a pre-engaged starter and therefore a different bell-housing, unfortunately these gearboxes are not compatible with a Rebel tailshaft extension so I've taken a section from one of these later bell-housing and welded it into my inertia gearbox.

The end result will be a Franken'Gearbox which will have synchromesh on all gears. Short throw remote gearchange, Pre-engaged starter and Hydrualicly operated Ford Roller Bearing Clutch, This is built using entirely New old Stock components with the exception of the Mainshaft and the case.

Overview of modified gearbox with remote change unfitted:


Section removed from original bell-housing:


Showing section from late pre-engaged box welded in and (unfinished) clutch operating shaft and arm fitted:


Arrangement of Ford release bearing - Note newly drilled inspection hole filled with rubber plug for checking bearing once fitted to car:



I've modified the flywheel from the standard 3 bolt fixing:....


And drilled and threaded the crankshaft to suit:....



As a reward for reading this far here's a Video of the Rebel razzing it's knackers off down the Military Road...

[Lord Sterling]

I really enjoyed that video! The Rebel kinda sounds like a mid 90s Max-Powered Mk1/2 Fiesta XR2, it looks a hoot to drive, the gear-change looks very easy and slick, probably better than most moderns.

[dollywobbler]

Lovely work. I was scrolling down this page thinking "this car needs white indicator lenses and some nicely painted wheels." Looks great now! Gearbox meddling also entertaining.

[RedSparrow]

This is amazing! such a great looking little car.
What are you engine plans?

[cort16]

20mpg. Ouch! I get 20 mpg from my Jag and it's a 4 litre v8 with a supercharger!

 

Anyway, great to see some serious enginneering put into this. I like the look of the franken gearbox. Did you tig that yourself?

[coalnotdole]

Thanks everyone - its a financially crippling time consuming project but every time i get in it to drive to the shops it puts a smile on my face!

 

20mpg. Ouch! I get 20 mpg from my Jag and it's a 4 litre v8 with a supercharger!

 

Anyway, great to see some serious enginneering put into this. I like the look of the franken gearbox. Did you tig that yourself?

Prep/cut&shut and tacking done by me, Main welds done by a old shipyard welder who isn't fazed by alloy castings full of sand and crap!. I only trust myself with TIG on steel/stainless and copper.

 

This is amazing! such a great looking little car.

What are you engine plans?

I'm building up a 750cc engine (same bore as the later 850cc but shorter stroke so lower piston speeds) Probably with a mentally big valve head and external camshaft driven oilpump. will run a High lift cam. The Block's also been bored out to take larger diameter (BMC A series) cam followers

 

 

Dave

[Angrydicky]

Wonderful little car, and great to see it looking so good!

[Mr_Bo11ox]

Absolutley fantastic. It looks like such a laugh to blezz around in, just brilliant man. 19.8/10 

[HillmanImp]

Its amazing what problems can crop up innit, you could buy the mintest rebel in the world and it could still be 6 months or less from having some of the steel reinforcers pop through the fibreglass with rust. You're doing such a thorough job, if you carry on like that theres no way a better Rebel can exist. 193.5/10

Why has your opinion of this gone down by approx 1000%?

 

This is ace. They really are a good looking car these.

[Joey spud]

This is the dogs bollocks,the fit and finish on that is something Tamworth could only of dreamt of.

My dad only ever had a full bike licence so as a family we went everywhere in these fine machines.

 

I've got a Rialto van stashed away for the future.i always wondered if a 3 pot Daihatsu engine could be mated to an equally small rwd gearbox to make a sensible powered weapon,but that said the 850cc ones are a cracking little engine

[garethj]

I've got a Rialto van stashed away for the future.i always wondered if a 3 pot Daihatsu engine could be mated to an equally small rwd gearbox to make a sensible powered weapon,but that said the 850cc ones are a cracking little engine

I put a cheeky bid on this very car when it was at the Dunstable scrapyard, my plan was to put a Bedford Rascal engine, gearbox & rear axle in for a comparatively powerful 45bhp.

 

But there's no way I'd have got it to this kind of standard, the car had a lucky escape

[coalnotdole]

A small update:

The replacement engine for the Rebel is now well underway - The crankshaft has been polished (which took 2 zirconium flap discs, 40meters of emery tape and 3 days) This should reduce stress risers and oil-cling.

The Crank, Flywheel, Clutch Cover, Timing Sprocket, Front Pulley etc have all been dynamically balanced down to less than half a gram. Each item was individually balanced before being assembled together - this means if I want to change the flywheel or another component in the future it will not necessitate stripping the whole engine down for re-balancing.

 

The connecting rods have been polished and balanced not only to the same weight but to the same weight distribution between little and big ends. Pistons (Hepolites) have been balanced as well. The Balancing was carried out by David Martin at Swaymar Engineering, a name that speaks for itself...

The crank, Rods, Flywheel etc are all brand new old stock items made before reliant quality control started to slip!.

 

Piccies:

Crankshaft after polishing:

 

 

And back from the Balancers:

 

 

 

 

Showing some of the holes drilled in the clutch cover for balancing:

 

 

And flywheel balancing:

 

 

Oil holes in the crank have also been lightly chamfered and the journals polished:

 

 

Front pulley has been faced up in a lathe as it was a rough casting,

I may have to swap this for a smaller toothed pulley depending on clearance around the external oilpump conversion:

 

 

Balance drillings:

 

 

Con Rods - You can just see where the third rod from the left has been turned in a lathe to remove meat from around the outer edge of the big end:

 

 

 

 

Nos Hepolites which were surprisingly well balanced straight out the box. Still - they're now all balanced to exactly the same weight!

 

 

Showing where material has been removed from the skirt:

 

 

And finally a pretty bit of paper to prove I spent lots of money!: