My new project - 1965 Morris Cooper S - HOY 500D

[Andrew1967]

Looks great in primer!
When did the overrider cut outs start ?

Not sure Nick.

Simon Wheatcroft mentioned that it shouldn't have cut outs but can't find the email or information on when they were added.

[Nick W]

oh yes my bmc shell hasn't got them, and thats from around march 66.....so it took em long enough to put them in

[Peter Laidler]

I seem to recall somewhere in my memory banks that the cut-outs weren't to help the punters but more to help the track assemblers at Cowley. If the bumpers came as an assembly - including the over-riders and corner bars they would always(?) chip the paint on assembly, no matter how delicately the caring and thoughtful workforce were. So that's the reason.

If the overriders were put on afterwards and bolted-up by the punter or garage say, the cut-out wasn't necessary and paint on the lip wouldn't chip. Or maybe it was the other way round

[Toby]

I seem to recall somewhere in my memory banks that the cut-outs weren't to help the punters but more to help the track assemblers at Cowley. If the bumpers came as an assembly - including the over-riders and corner bars they would always(?) chip the paint on assembly, no matter how delicately the caring and thoughtful workforce were. So that's the reason.

If the overriders were put on afterwards and bolted-up by the punter or garage say, the cut-out wasn't necessary and paint on the lip wouldn't chip. Or maybe it was the other way round

Complete bumper assemblies will indeed foul the bumper lip, so it was indeed done to aid assembly speed in the factory

[Andrew1967]

To keep people happy, here are some pics of yesterdays work ...

Filled in the overrider cut outs and epoxied the underside wing/inner wing areas ..

[Andrew1967]

Just been looking at the pics on the first page and realised just how far this has come in a couple years

When doing the work, it doesn't seem like a lot is being done.

[Peter Laidler]

I've been following this too....., a sort of moral supporter. It's not just work Andy, it's a work of art!

[Andrew1967]

Thanks Peter and after all, you did see HOY in the metal (or is that rust ) before I started the rescue.

[1ely]

I too have seen the before shell in the flesh and remember thinking to my self has this man gone mad! You do see a lot of shell restorations these days, but I think I am safe in saying that you restored areas I have never seen tackled before, good on you Andrew, you have made a cracking job! Looking forward to future progress.
Francis

[Andrew1967]

Thanks Francis

Yes, many people thought I was mad ... I had to ask myself a few times 'What the f*** are you doing this shell for Andrew, just re-shell it like any sane person would do !! '

I like a challenge

[tedmcedd]

Looking fab!

[Costafortune]

I have to say, you couldn't design a worse rust trap that a Mark 1/2 Mini inner wing!

[Old English White]

Don't forget that the earliest cars had a shield fitted which at least gave a little protection to that area

[Andrew1967]

I have to say, you couldn't design a worse rust trap that a Mark 1/2 Mini inner wing!

I don't know, the ADO16 inner wing area is up there with Minis

Just as well our cars don't go out in the winters any more !

[Dearg1275]

Who says our cars don’t go out in the winter any more?

D

[Andrew1967]

Well, to keep Peter and Richard happy, here is an update

Work has slowed somewhat over the past couple of months with other things taking my mind off the job. Some of that being obtaining more parts from the usual source and a couple of other places.

HOY is temporarily out of the rotisserie and sat on planks supported by axle stands in order to fit and gap the bootlid before doing a couple of minor repairs to the inner skin. I'll also be doing the same to the doors.

The shell is now fully epoxied and most of the filling done and re-epoxied as appropriate. What a sh*tty job prepping the boot area is - awkward and lots of bits to catch fingers on.

I managed to find a perfect, original drivers door a couple of weeks ago, a fortnight or so after buying a 99% perfect drivers door (only requires work to outer skin behind lower hinge - other than that it is totally rust free and original !) So I now have two drivers doors. I'll probably repair and keep the first bought door in case i get another project !!

So, once the doors, bonnet and bootlid are in epoxy primer, I'll make a start on some mechanical work, probably the suspension components first and then the engine and gearbox.

Here's a few pics ....

[Andrew1967]

A few more including tonights boot lid repair to inner skin and adjacent replace outer skin lip.

[richardACS]

Thank you for highlighting the Dearg 1275 project, there is so much good information available to us through these projects and the skill on display is something else!

Very envious of your lovely boot floor and of course the slingers!

[Daz1968]

Superb work, not best time of year for working on cars though,
Not sure if you know, but as you have been so careful to get everything spot on, the battery box is later one, but only the parts where the battery clamp bolts go is different so easy to sort if you want to,
They are smaller and only have the one hole, but I am only mentioning it in case it will bother you.

But as I said the car is superb.

[Andrew1967]

I’ll check that out Darren and if easy to correct as you say, I’ll do that .

The battery box came fitted to the (probably) mid 80’s AustinRover labelled boot floor assembly.