Main Phases of the whole Project Phoenix-22-Dates
1-Select-aquire-collect and store car.09-02-10
2-List everything present
3-formulate missing items into a purchase list.
4- Assess,measure,photograph everything as soon as possible after collecting car.
5- Strip all mechanicals.
6- Strip all Electricals.
7-Take out trim ,bodywork ie wings and doors,then brightwork-but leave the car mobile in the Garage.Think of renovation mobility or build a body roller or turner.
8-Aquire jig or gather metal for roller-turner or rotissorie.
9-Assemble Rotissorie for testing.completed by 03-09-2011
10-Raise chassis cab,check lighting and other garage equipment, now finally measure the car and record everything, on the 4 door Saloon plan.This will be the last time before cutting out and or making body changing decisions cab suspended and weight tested (safe and fit for purpose) 28-09-2011 .Final rotisserie construction and suspension of chassis cab on 29-10-2011. Attach Chassis Cab bracing bars, inside cab 31- 10-2011 measure and cut bracing bars for welding
11-Cleaning all the body and paint stripping on required areas to fully assess the condition including underneath.
Sadly this phase did not include the complete and final cessation of all physical activity due to medical considerations.
It is not yet know,or estimated what is to become of the project,given these circumstances. In any case it certainly will not unduly affect my interest in owning running and maintaining a car of the Marque-even though this particular car activity has to stop,I will keep posting up on here and amend matters accordingly 25-12-2012
The rebuild of the car has been taken over by (Chesney) Jack ! Pugh, a young gentleman on the morrisminorowners.co.uk. Both Jack and his Father Ken , have a big workshop and warehouse in Leeds,they will be posting up their progress on the end of the "Phoenix" thread as above.
12- De-rusting underneath and cutting to replace panels , MIG welding -letting in new metal.
13- De-rusting inside Cab and welding new metal in, seam sealing and primer or undercoat as required.Preparing all detached panels-doors-bonnet-boot lid- front and rear wings.
14- Paint prep and sealing, including all running gear-fit road springs and finished axle.
15- Renovate and final paint prep on other items, including ancillaries-Doors-Bonnet-Boot-Exhaust-Grill-Radiator-Wings-Lights-Running gear-Trim-Bright-work-Engine-Gearbox--wheel rims. Final purchase of all missing items.
16 Test fitting all items (except engine and gearbox) adjust as required, before final painting of top coat, then disassemble everything for final paint.
17-Full painting of wheeled body (Chassis Cab) and ancillaries.
18- Refit everything finally- Total fit (including Engine and Gearbox) and paint touch ups,as required and waxoyle.
19 Fire up engine-test all running gear as much as possible.
20-Change from renovation wheels, to new rims and new tyres-previously balanced-tracking-pre MOT full check.
21-MOT test.
22 Change Insurance to, on the road status,change vehicle tax status. Road tax as Historical vehicle-end of project.
It is my intention to enjoy keeping the car on the road through , and useing well into my "Senior Years".
During this time I am hoping to gradually "up-spec", or modify it-as I assess it- through it's daily use.
I am hoping to complete a rolling renovation on the car to- "enable it to be used as a unique historical vehicle ,with some modernity, which does not detract from it's Historical status and feel".
This is the third part of an article by Cliff Lloyd, one of our members in Yorkshire – and describes how, despite difficulties, he hopes his project will reach a successful conclusion.
He has been cleared to re start some physical activity,(although still under Physio supervision) he is now back in the Garage-and has made such further progress has he hopes will continue the interest on the Website, and will help complete the mission.
Due to these unexpected delays, the Project Estimated End Date-Obviously Far Fetched (PEED-OFF) has now been extended to the first week in June 2012. It is hoped that this new date will coincide with a local Carnival and Her Majesties Silver Jubilee activities.( quite apt really considering some of these cars were built, and renovated over this same time period 1952-2012.
Another dearest wish is to join in a Rally day which will be arranged to drive down to London to support Great Britain in a special day during the 2012 Olympics.
The Phoenix Project- by Cliff Lloyd
Part Three of this report.
Phase 9. Once all of the items were removed from the Monocoque body shell, leaving just a bare Cab, it was then that the home made Body-Jig Rotisserie, system was assembled. This suspending system was designed by me, and had to comply with a set of specific criteria that I drew up to accommodate my personal requirements.
The Jig now in its final Mark 5 version, will allow the Monocoque to be suspended, give full rotational access to all body parts, in a safe, strong, mobile, cheap and adaptable manner.
At the time of writing, the monococque is being braced by inserting ,longitudinal and cross bars inside the cab main body areas, so that when cutting out of all the rotted, rusted areas, there is no distortion.
I have noted that during this main bodywork phase, great care should be exercised to ensure that areas being cut out do not affect the overall strength or rigidity of the car.
Special care will be taken, If any repairs are carried out in an area of structural importance, then replacement metal should make it comply with body measurements taken already. These measurements were taken when the car was in its normal stressed bodyweight, with engine gearbox and running gear in situ and then when in an un stressed ,or stripped state.
Phase 10. This phase is imminent, and will be the longest phase of the whole plan- Body work. It is one which many people would maybe find daunting, but I am quietly confident that everything is in place to give me a successful outcome.
As I progress through all of the next 12 phases, I will update my website. This can be found at (morrisminor4doorrescueproject.weebly.com) .So you are aware of what-is yet to come- in the overall plan, here it is !
Phase 9-Assemble Rotisserie for testing. Completed by 03-09-2011
Phase 10-Raise and check safety of chassis cab, check lighting and other garage equipment required, now finally measure the car and record everything again, add these to the 4 door Saloon plan. This will be the last time before cutting out and or making body changing decisions ,cab suspended and weight tested (as safe and fit for purpose) 28-09-2011.Final rotisserie construction and suspension of chassis cab on 29-10-2011. Chassis Cab bracing bar plans, measurements inside cab 31- 10-2011. Measure and cut bracing bars for welding into the .
Phase 11-Cleaning and assessing all the bodywork. Paint stripping if required in any area, to assess the overall condition of the metal- including underneath.
Phase 12- Derusting and cutting to replace panels, using the MIG welding technique -letting in of all new metal. When the Sills, A to B and B to C post repairs are carried out- all door shells will be temporarily refitted to check alignment gaps. Same for the Bonnet, wings and boot area repairs are completed as appropriate.
Phase 13- Derusting inside Cab and letting in all new metal, apply rust killer acid then seam seal, with the application of primer or undercoat, Waxoyl to box sections and Boxing plate areas as required. Complete the underneath-electrics, fuel, handbrake wires and brake pipes as required. Prepare and renovate all detached panels-doors-bonnet-boot lid- front and rear wings. Complete brake, bearing, suspension bush overhaul
14- Paint prep and sealing, including all running gear-fit road springs and prepare the finished axle and renovation wheels for fitting. Complete all underneath work to lower the car from the rotisserie.
15- Final paint prep on other items as required, including all ancillaries-Doors-Bonnet-Boot-Exhaust-Grill-Radiator-Wings-Lights-Running gear-Trim-Bright work-Engine-Gearbox--wheel rims. Final purchase of all missing items, including Tyres.
START OF CLEAN PHASE
16 Test fitting all items (except engine and gearbox) adjust as required, then disassemble before final painting of top coat.
17-Full painting of wheeled body (Monococque Chassis Cab) and ancilliaries.
18- Refit everything finally- Total fit (including Engine and Gearbox) front and rear windscreens and trim with all main body items listed above paint touch ups, as required. Application of final Waxoyl.
19 Fire up engine-test all running gear as much as possible.
20-Change from renovation wheels, to new rims and new tyres-previously balanced-with tracking checked-pre MOT full check.Final body polish/clean
21-MOT test.Ammend or fix MOT problem areas as required.
22 Change Insurance from Garaged to, on the road status, change vehicle tax status. Road tax as Historical vehicle-end of project.
It is my intention to enjoy keeping the car on the road through , and useing well into my "Senior Years".
During this time I am hoping to gradually "up-spec", or modify it-as I assess it- through it's daily use.
I am hoping to complete a rolling renovation on the car to- "enable it to be used as a unique historical vehicle ,with some modernity, which does not detract from it's Historical status and feel".
The various renovation phases will then be followed in a logical planning order.
(a) Full cleaning and de-rusting of the underneath of the car, around all suspension areas, Phases 11 to 14. and then cutting out and MIG welding in new metal. Due to the possibility of additional welding on the inside, burning paint off from underneath, only “Weld- through primer” will be added to the rust killer.
(b) Inside of the car is next, de-rusting and cutting out areasPhases 15 to 18, sees the transition from the dirty to the clean phases, and includes renovation of all ancillaries then, doors, wings ,bonnet, boot, running gear, glass, trim, bright work, engine and gearbox, wheels and tyres.
Phase 16 - means test fitting as many items as possible so as to not damage the new paint ,which the application of is in the next phase.
Phase 17- is to fully paint all the “wheeled monococque” body and main items, which have just been renovated but not attached to the body for example, wings, doors, bonnet, boot lid.
Phase 18-is to re fit everything for example, glass, screen rubbers, head lining, seating, carpeting, electrics, etc.
The final part of this phase is to fit everything together.
Final details should allow enough time to attend to important items like, with final rust proofing and anti rust protection, both above and below the body shell, before a test fire up of the engine is conducted-Phase 19
Phase 20, is to fit new tyres to the newly refurbished wheels. Then carefully go through the pre MOT checks and snagging list.
Phase 21, will hopefully see “Phoenix”, with a Certificate that she has not seen for 20 +years. Then to change her car insurance from off the road,in the Garage having a re build,to being fully comprehensive cover on the road with an agreed valuation figure agreed and supported by the Rebuild manual Log book.
Final Phase 22- to write off to DVLA for her “Historical” Tax Disc, to be displayed during the reborn phase of her existence, hopefully to see her last another 50 years
Notes to be added at liesure-trailer hire £35 £60 fuel $53.72 parts £50 diff=£198.72. 23/05/2010.
Owed 103 days-4 days worked-since started 9 days-hours 15 (9 hours on the collection day = 6 doing pictures.
SPEED=696 days to 19/04/2012-
saved already £2461.00.
Drained the Diff-left the plug out over night
Engine oil left in-spark plugs left in and oil in bores
Gearbox cross member bolts back in and left easier to assemble when finished.
Heater out =matrix.
Doors hinges off the doors.leave them on the car ?
Slacken all wheel nuts.
Chains on engine block
Both front wings
Brake tubes
Heater pipes disconnect
Fuses and control box
Wiring harness washer bottle
2-List everything present
3-formulate missing items into a purchase list.
4- Assess,measure,photograph everything as soon as possible after collecting car.
5- Strip all mechanicals.
6- Strip all Electricals.
7-Take out trim ,bodywork ie wings and doors,then brightwork-but leave the car mobile in the Garage.Think of renovation mobility or build a body roller or turner.
8-Aquire jig or gather metal for roller-turner or rotissorie.
9-Assemble Rotissorie for testing.completed by 03-09-2011
10-Raise chassis cab,check lighting and other garage equipment, now finally measure the car and record everything, on the 4 door Saloon plan.This will be the last time before cutting out and or making body changing decisions cab suspended and weight tested (safe and fit for purpose) 28-09-2011 .Final rotisserie construction and suspension of chassis cab on 29-10-2011. Attach Chassis Cab bracing bars, inside cab 31- 10-2011 measure and cut bracing bars for welding
11-Cleaning all the body and paint stripping on required areas to fully assess the condition including underneath.
Sadly this phase did not include the complete and final cessation of all physical activity due to medical considerations.
It is not yet know,or estimated what is to become of the project,given these circumstances. In any case it certainly will not unduly affect my interest in owning running and maintaining a car of the Marque-even though this particular car activity has to stop,I will keep posting up on here and amend matters accordingly 25-12-2012
The rebuild of the car has been taken over by (Chesney) Jack ! Pugh, a young gentleman on the morrisminorowners.co.uk. Both Jack and his Father Ken , have a big workshop and warehouse in Leeds,they will be posting up their progress on the end of the "Phoenix" thread as above.
12- De-rusting underneath and cutting to replace panels , MIG welding -letting in new metal.
13- De-rusting inside Cab and welding new metal in, seam sealing and primer or undercoat as required.Preparing all detached panels-doors-bonnet-boot lid- front and rear wings.
14- Paint prep and sealing, including all running gear-fit road springs and finished axle.
15- Renovate and final paint prep on other items, including ancillaries-Doors-Bonnet-Boot-Exhaust-Grill-Radiator-Wings-Lights-Running gear-Trim-Bright-work-Engine-Gearbox--wheel rims. Final purchase of all missing items.
16 Test fitting all items (except engine and gearbox) adjust as required, before final painting of top coat, then disassemble everything for final paint.
17-Full painting of wheeled body (Chassis Cab) and ancillaries.
18- Refit everything finally- Total fit (including Engine and Gearbox) and paint touch ups,as required and waxoyle.
19 Fire up engine-test all running gear as much as possible.
20-Change from renovation wheels, to new rims and new tyres-previously balanced-tracking-pre MOT full check.
21-MOT test.
22 Change Insurance to, on the road status,change vehicle tax status. Road tax as Historical vehicle-end of project.
It is my intention to enjoy keeping the car on the road through , and useing well into my "Senior Years".
During this time I am hoping to gradually "up-spec", or modify it-as I assess it- through it's daily use.
I am hoping to complete a rolling renovation on the car to- "enable it to be used as a unique historical vehicle ,with some modernity, which does not detract from it's Historical status and feel".
This is the third part of an article by Cliff Lloyd, one of our members in Yorkshire – and describes how, despite difficulties, he hopes his project will reach a successful conclusion.
He has been cleared to re start some physical activity,(although still under Physio supervision) he is now back in the Garage-and has made such further progress has he hopes will continue the interest on the Website, and will help complete the mission.
Due to these unexpected delays, the Project Estimated End Date-Obviously Far Fetched (PEED-OFF) has now been extended to the first week in June 2012. It is hoped that this new date will coincide with a local Carnival and Her Majesties Silver Jubilee activities.( quite apt really considering some of these cars were built, and renovated over this same time period 1952-2012.
Another dearest wish is to join in a Rally day which will be arranged to drive down to London to support Great Britain in a special day during the 2012 Olympics.
The Phoenix Project- by Cliff Lloyd
Part Three of this report.
Phase 9. Once all of the items were removed from the Monocoque body shell, leaving just a bare Cab, it was then that the home made Body-Jig Rotisserie, system was assembled. This suspending system was designed by me, and had to comply with a set of specific criteria that I drew up to accommodate my personal requirements.
The Jig now in its final Mark 5 version, will allow the Monocoque to be suspended, give full rotational access to all body parts, in a safe, strong, mobile, cheap and adaptable manner.
At the time of writing, the monococque is being braced by inserting ,longitudinal and cross bars inside the cab main body areas, so that when cutting out of all the rotted, rusted areas, there is no distortion.
I have noted that during this main bodywork phase, great care should be exercised to ensure that areas being cut out do not affect the overall strength or rigidity of the car.
Special care will be taken, If any repairs are carried out in an area of structural importance, then replacement metal should make it comply with body measurements taken already. These measurements were taken when the car was in its normal stressed bodyweight, with engine gearbox and running gear in situ and then when in an un stressed ,or stripped state.
Phase 10. This phase is imminent, and will be the longest phase of the whole plan- Body work. It is one which many people would maybe find daunting, but I am quietly confident that everything is in place to give me a successful outcome.
As I progress through all of the next 12 phases, I will update my website. This can be found at (morrisminor4doorrescueproject.weebly.com) .So you are aware of what-is yet to come- in the overall plan, here it is !
Phase 9-Assemble Rotisserie for testing. Completed by 03-09-2011
Phase 10-Raise and check safety of chassis cab, check lighting and other garage equipment required, now finally measure the car and record everything again, add these to the 4 door Saloon plan. This will be the last time before cutting out and or making body changing decisions ,cab suspended and weight tested (as safe and fit for purpose) 28-09-2011.Final rotisserie construction and suspension of chassis cab on 29-10-2011. Chassis Cab bracing bar plans, measurements inside cab 31- 10-2011. Measure and cut bracing bars for welding into the .
Phase 11-Cleaning and assessing all the bodywork. Paint stripping if required in any area, to assess the overall condition of the metal- including underneath.
Phase 12- Derusting and cutting to replace panels, using the MIG welding technique -letting in of all new metal. When the Sills, A to B and B to C post repairs are carried out- all door shells will be temporarily refitted to check alignment gaps. Same for the Bonnet, wings and boot area repairs are completed as appropriate.
Phase 13- Derusting inside Cab and letting in all new metal, apply rust killer acid then seam seal, with the application of primer or undercoat, Waxoyl to box sections and Boxing plate areas as required. Complete the underneath-electrics, fuel, handbrake wires and brake pipes as required. Prepare and renovate all detached panels-doors-bonnet-boot lid- front and rear wings. Complete brake, bearing, suspension bush overhaul
14- Paint prep and sealing, including all running gear-fit road springs and prepare the finished axle and renovation wheels for fitting. Complete all underneath work to lower the car from the rotisserie.
15- Final paint prep on other items as required, including all ancillaries-Doors-Bonnet-Boot-Exhaust-Grill-Radiator-Wings-Lights-Running gear-Trim-Bright work-Engine-Gearbox--wheel rims. Final purchase of all missing items, including Tyres.
START OF CLEAN PHASE
16 Test fitting all items (except engine and gearbox) adjust as required, then disassemble before final painting of top coat.
17-Full painting of wheeled body (Monococque Chassis Cab) and ancilliaries.
18- Refit everything finally- Total fit (including Engine and Gearbox) front and rear windscreens and trim with all main body items listed above paint touch ups, as required. Application of final Waxoyl.
19 Fire up engine-test all running gear as much as possible.
20-Change from renovation wheels, to new rims and new tyres-previously balanced-with tracking checked-pre MOT full check.Final body polish/clean
21-MOT test.Ammend or fix MOT problem areas as required.
22 Change Insurance from Garaged to, on the road status, change vehicle tax status. Road tax as Historical vehicle-end of project.
It is my intention to enjoy keeping the car on the road through , and useing well into my "Senior Years".
During this time I am hoping to gradually "up-spec", or modify it-as I assess it- through it's daily use.
I am hoping to complete a rolling renovation on the car to- "enable it to be used as a unique historical vehicle ,with some modernity, which does not detract from it's Historical status and feel".
The various renovation phases will then be followed in a logical planning order.
(a) Full cleaning and de-rusting of the underneath of the car, around all suspension areas, Phases 11 to 14. and then cutting out and MIG welding in new metal. Due to the possibility of additional welding on the inside, burning paint off from underneath, only “Weld- through primer” will be added to the rust killer.
(b) Inside of the car is next, de-rusting and cutting out areasPhases 15 to 18, sees the transition from the dirty to the clean phases, and includes renovation of all ancillaries then, doors, wings ,bonnet, boot, running gear, glass, trim, bright work, engine and gearbox, wheels and tyres.
Phase 16 - means test fitting as many items as possible so as to not damage the new paint ,which the application of is in the next phase.
Phase 17- is to fully paint all the “wheeled monococque” body and main items, which have just been renovated but not attached to the body for example, wings, doors, bonnet, boot lid.
Phase 18-is to re fit everything for example, glass, screen rubbers, head lining, seating, carpeting, electrics, etc.
The final part of this phase is to fit everything together.
Final details should allow enough time to attend to important items like, with final rust proofing and anti rust protection, both above and below the body shell, before a test fire up of the engine is conducted-Phase 19
Phase 20, is to fit new tyres to the newly refurbished wheels. Then carefully go through the pre MOT checks and snagging list.
Phase 21, will hopefully see “Phoenix”, with a Certificate that she has not seen for 20 +years. Then to change her car insurance from off the road,in the Garage having a re build,to being fully comprehensive cover on the road with an agreed valuation figure agreed and supported by the Rebuild manual Log book.
Final Phase 22- to write off to DVLA for her “Historical” Tax Disc, to be displayed during the reborn phase of her existence, hopefully to see her last another 50 years
Notes to be added at liesure-trailer hire £35 £60 fuel $53.72 parts £50 diff=£198.72. 23/05/2010.
Owed 103 days-4 days worked-since started 9 days-hours 15 (9 hours on the collection day = 6 doing pictures.
SPEED=696 days to 19/04/2012-
saved already £2461.00.
Drained the Diff-left the plug out over night
Engine oil left in-spark plugs left in and oil in bores
Gearbox cross member bolts back in and left easier to assemble when finished.
Heater out =matrix.
Doors hinges off the doors.leave them on the car ?
Slacken all wheel nuts.
Chains on engine block
Both front wings
Brake tubes
Heater pipes disconnect
Fuses and control box
Wiring harness washer bottle