1968 Ford Anglia Project
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The rebuild starts !

26/10/2014

 
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After a couple of weeks off following the marathon cleaning and painting session I managed to get out in the garage this weekend. So, now the car is fully clean and tidy (except for one little blemish on the drivers front wing) my attention turned to starting to re-install the mechanical parts of the car.

First up was the front axles, these hubs were put on, the bearings looked to be in pretty good order so just re-packed them with grease and then bolted them back together with new nuts and captive system.  All runs smoothly with no wobble, grinding  or tightness. I then put the uprights, anti roll bar, steering rack and TCAs back in the car to see what it all looked like and to start to get the alignment right (camber and toe).

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All looked generally OK and except there is a bit too much camber for my liking. After a bit of a search it looks like the top mounts are Alachi 105e ones with added camber and caster.  With my TCAs wound in right the way there is about 4 degs of camber - I was hoping for something around 1.5 degs.  So after an exchange of emails I have ordered the Alachi eccentric fully adjustable top mounts, I can then re-use the bearings and circlips.

The rear end was then put back together, after much deliberation I have decided to stick with the 4.125:1 diff and see how it goes, I have tried a couple of times to get a 3.77:1 or 3.54:1 but with out luck or they were too expensive so I will wait for a while before deciding.  The rear end went back together well using some spacers made from the old drum brake backing plates. I also decided to butcher the Caprisport caliper mounts to fit behind the axle case end flange. After much grinding (metal and teeth) they now fit. Just need some longer studs and replacement brake parts (disc and pads) and all of the running gear will be sorted.

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With the running gear well on the way to being restored I turned my attention to a few small jobs. Firstly, I had a mate's Dad pop round to have a look at welding up some engine mounts, modifying the cross member (taking off the mounts) and possibly welding up an exhaust (Spencer Ashley kit). Second on the list was to re-build the pedal box, do an initial fit and mount the brake master cylinder, all goes in well. Thirdly, was to look at demist, I bought a couple of cheap 150w cigarette lighter socket powered demisters which I have taken apart and now have running off one set of switches (the plan is to box them up and use one each side through the screen vents). Finally, I sent off drawings and the OEM sump to have a new one built. Got the pictures back today, and it is looking very good. I initially  was expecting a steel sump but  Crapengineering who are making it has decided to go with aluminium and I have no problems with that. I am looking forward to getting it and seeing how it all fits together.

So, the next few weeks will consist of buying the final parts for the running gear, installing them, finalising the designs for the mounts and getting those made up. So, by Christmas I am hoping to have all of the running gear in and mounted. I can then start on plumbing, brake runs and finally getting onto the electrics.

I have a shiny bottom

7/10/2014

 
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Three weekends ago I finished off underside preparation by cleaning down the surface with a petrol soaked rag to remove the last of the underseal, wash with POR15 Aquaclean, wash with water, applied POR15 Metal Prep and carried out a final clean water wash down. This was then wiped down and left for a week to fully dry out. Then began the mammoth job of painting the rest of the underside, three days later and the whole of the underside had had two coats of KBS Rustseal, all seams sealed and a final coat of KBS Rustseal. So the whole process was -

  • Wirebrush of all lose paint and undeseal
  • Wash down with petrol soaked rag
  • Clean with POR15 Aquaclean
  • Wash down with clean water
  • Apply POR15 Metal Prep
  • Wash down with clean water
  • Wipe down with dry cloth
  • Leave for a week in garage to dry
  • Apply two coats of KBS Rustseal
  • Seal Seams with Tigerseal
  • Apply a final coat of KBS Rustseal

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I disassembled the rear axle, removed the diff and drive shafts, cleaned these, the 5 link bars, front uprights, brake brackets and front hubs. Painted all of these with Hammerite so they are all ready to re-fit once the paint has been given time to go off fully. I also trial fitted the rear disc brackets. Unfortunately the Caprisport brackets that bolt onto the outer face of the axle casing do not fit  i.e. put the disc in the wrong place relative to the caliper (about 10-12mm out). After a measure up I concluded that brackets that fitted on the rear of the axle case flange were the once to get, so have ordered a set from Mk2mania.

I also ordered and received the adaptor plate for the throttle bodies from Lasermaster, looked a pretty good fit straight off but with a few slight tweaks and the bolt/stud holed drilled it looks like it will do just the job.  Only job left to do it to get a larger countersink to further recess the bolts for the adaptor to head connection.

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The final job on chassis prep, after finishing the painting last week was to bolt together the engine, gearbox and bell housing and do a trial fit so that I could get measurements for the sump, engine mounts and gearbox mount. It all looks pretty good and looks like I will have some good space around the engine for the throttle bodies and the exhaust. Following these measurements I have developed CAD models of the sump/block mating face and mounting plates for the engine and have sent the sump ideas off for a quote.

So I am now in a position where I can start to bolt parts back onto the car rather than take them off. Rear axle will be first, then the front uprights which I suspect will take a while to get into a position where the camber/toe etc is correct and then I can start of ordering the engine mounts and possibly the exhaust and whilst these are making their way here I can look at door cards and assembling the doors/seals etc. and finalising the designs for the petrol tank , radiator header tank, catch tank and washer bottle and working out the coolant system .

    Father & Son Team

    I'm a mid-life crisis sufferer who just had to have another project.

    My son is impressionable and willing to learn the ways of "the petrol".

    Together we will learn, laugh, cry and probably fight in the creation of an automotive gem.


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