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Good to see your progress too Surfari man!

Incidentally, did you ever ask the local cops if it was a ex-cop van?

Looking great, lovely work.

The epoxy mastic sounds an interesting alternative .

I think I prefer epoxy to Powder coat. Would like to experiment with it on my next project. What make is it and what was application and finish like?
Thanks
Mark

mini_surfari wrote: ↑Mon Oct 04, 2021 1:35 pm Been a while, and progress on the shell has stalled, hopefully there will be a big push on it in the next few weeks.

In the mean time, cleaning up parts and painting.

Decided to swerve the powder coating and have gone with epoxy mastic instead. With a bit of luck this will hold up well!











Had the rear subframe blasted even though it was new... lucky we did as there was plenty of surface rust under the e-coat.











There really isn't a great deal to do now. Once the body has been painted it should fly together pretty quickly!

rolesyboy wrote: ↑Tue Oct 05, 2021 6:39 pm I think I prefer epoxy to Powder coat. Would like to experiment with it on my next project. What make is it and what was application and finish like?
Thanks
Mark

Thanks for the comments.

Peter, had no luck with proving it is an ex-police van at all. So will continue as we had originally intended before purchasing.

I've also been made aware I have the brake pipe on the wrong side of the lip, so will be swapping that over .

Mark, Its rust busters epoxy mastic 121, I added 20% thinners which is the maximum they recommend, sprayed at 50 psi with a 1.8mm tip, and I think the finish has come out well, (not a deep gloss, so looks reasonably OEM). Certainly comes out thick but it seems to self level. It's not UV resistant, however I'm hoping it'll hold up well underneath the car. The data sheet does say it can be over coated though.

It has extremely good reviews, I found it through 'Trevs Blog' on youtube. Its not the cheapest in terms of epoxy paint, but we're happy with the finish so only time will tell if it was worth it.

We also filled all the cavities in the subframe with dynax S50 to try and help with protection.

Cheers, Oli

Thanks. I used an epoxy mastic a few years back. Messy affair and came out very thick so took some fathoming with the nozzles.
As you say seems to self level well and is very resilient. I will try the one you suggested
Cheers

Things have been progressing slowly,

The seam strips now fit better after come manipulation.



Body work continues....





And the engine has been built up... hopefully it can be dropped in as is (minus carbs)??



Fingers crossed it'll be finished for summer..... famous last words.

Looking good, seems we are both at the same stage of a huge amount of sanding!

I found it much easier installing the engine & radiator as one unit. Saved messing around trying to get the rad in

hi
engine looks great i found that if i left out the bolt on the clutch cover that is obscured by the lower part of the sub frame that i could change the clutch plate with out taking the engine out made life a lot easier
also setting up the austin 1800 gear box so i can remove the clutch plate in my mini clubman with v8 rover motor
well you have done a great job on this van i had one years ago which i wanted to do up as a family car but we moved and i had to pass it on i think it ended as a trailer what a waste
cheers roger mcnab

Getting an engine in, future maintenance and life generally will certainly be a whole lot simpler without the waste-of-space inner wing fan shroud - as per the later cars. It's not too late to chop it out and make good.

I don't see an inner wing shroud, Peter - or do you mean the grille vents in the wing?

Al

The inner wing shroud I refer to is the shroud spot welded to the inner nearside;left hand inner wing (we used to call it the flitch panel ?). It extends from the slatted inner wing to the radiator. This shroud was deleted from cars during the 70's

I thought that's what you meant, where chassis plates were fitted. But there isn't one fitted in the photos, so I was confused by your comment about not too late to chop it out to ease maintenece down the line?

Al

Progressing again,

Filler work, and a coat of Epoxy.

What a transition! Shell is looking amazing!

That is progressing nicely.

Amazing work. Looks fantastic!

Small update,

Inside and engine bay have now been coloured in.







And other small jobs have been done to make the rebuild as quick as possible.

Picked up some good rear light units as Beaulieu last year, so lenses have been swapped and cleaned up etc.



And the headlining was just a little too rough to go back in sadly, so a new one has been fitted. Once our head was round it, not a bad job, just slow.

Looking great … bet you can’t wait to get the outside painted and really get on with the fitting up.

Andrew1967 wrote: ↑Tue Mar 29, 2022 5:59 pm Looking great … bet you can’t wait to get the outside painted and really get on with the fitting up.

Thankfully that time has now come, just have to try and not scratch anything now!

Wheels have been powder coated, really pleased with the job and colour... Now to find someone to fit the tyres without marking them!




Had a bit of a push on the shell, this weekend, will let the pics do the talking.









Also, when we buttoned up the engine, we used a copper head gasket, but heard a few horror stories recently, so tempted to swap it out for a victor reinz gasket, any thoughts?