Restoring my Berlinetta

[scott h]

Hi just (re)joined the club.
I first built my Berli in the early nineties, chassis No. 1515SBV8. Many of you will know this means it is Sierra based with a Rover V8. Fitting the engine was a
major task not helped by little or no technical back up from the factory. I was told the guy who was developing the V8 installation had left half way through the job! Anyway I solved each problem on my own one by one and my Marlin was registered in Dec 1993. It served as daily transport until 1999 when the call of motorsport won the battle for my time and money! The Marlin was left in the garage unloved and in slow decline, but there is a happy ending because I have rediscovered my enthusiasm for her and a total restoration is underway.
I was never totally happy with the V8. There was not enough room for a big enough radiator and so overheating was a problem. I even tried a second radiator under the boot!Other problems were the brakes. Due to lack of space I relocated the Sierra brake servo and operated it by a home made linkage but I was never happy with it although it passed each MOT. The other thing was low MPG.
So after much thought out goes the V8 and in goes a Vauxhall red top c20xe. I hope this will solve many of the aforementioned problems mainly due to more room in the engine bay, and use of injection and 16v will help the mpg. I hope the performance will be similar as both engines are about 150hp.
Other things I plan are to sand blast the chassis but I'm unsure whether to paint it or powder coat it or even galvanize it. Any advice appreciated. The standard Sierra rear end will be replaced with one from an XR4 with a viscous diff and disc brakes. I want to fit larger brakes to the front too.
I was a member of the club in the nineties and look forward to being a member again.

[cameronfurnival]

Re: Restoring my Berlinetta

Hi SCott and welcome! Would love to see some pics of it

[scott h]

Re: Restoring my Berlinetta

Got lots of pics but I'm a novice at computers, give me a car to work on and I'm fine but ask me to post pics and I will have to find out how! Got any advice? The pics are on my computer so should be quite easy once I know how.

[mark kessell]

Re: Restoring my Berlinetta

Hi scott

I am currently doing much the same as you on a roadster, it's been off the road for 14 years.

I decided to get the chassis galvanised , so its like starting from scratch again building the kit.

I think that's the best way to stop any rust, and I am also fitting all stainless nuts and bolts

Great fun, enjoy your rebuild whichever route you take

Mark

[scott h]

Re: Restoring my Berlinetta

Hi Mark
Think I probably will go for galvanizing but I've got a way to go before that. Right now I've just finished mounting the engine and box. Had to do this first before removing the body to make sure it fits. Trying to think of any welding for mounts etc now so that I don't have to touch it after it's galvanized or whatever I decide on. When I first built the car I used a number of stainless bolts but now that I'm stripping it I wish I had used more! This time it will be stainless where ever possible, bearing in mind you are not supposed to use them for high loads like suspension etc
Scott

[cameronfurnival]

Re: Restoring my Berlinetta

HI Mark - try clicking here for uploading photo tips - if you need help just shout )

[Robert in Cumbria]

Re: Restoring my Berlinetta

Hi Mark
Think I probably will go for galvanizing but I've got a way to go before that. Right now I've just finished mounting the engine and box. Had to do this first before removing the body to make sure it fits. Trying to think of any welding for mounts etc now so that I don't have to touch it after it's galvanized or whatever I decide on. When I first built the car I used a number of stainless bolts but now that I'm stripping it I wish I had used more! This time it will be stainless where ever possible, bearing in mind you are not supposed to use them for high loads like suspension etc
Scott

Scott,

I would recommend galvanising if it's within your budget. There are some things you need to be aware of though. You will have to drill the hollow sections of the chassis with at least 10mm holes, maybe larger, at each end of each section because the galvanising has to be done inside and out, a closed hollow section can cause an explosion with deadly consequences because the heat >450ºC causes the air inside the closed chamber to expand significantly while the metal of the frame is weakened by the heat. The rupturing of the closed section can be very dangerous zinc tanks have been known to be almost emptied by such events with many deaths. Drilling has to be done so that air can escape and zinc can enter during immersion and then when the frame has been soaked it has to drain as it is lifted out of the zinc tank.

The holes can be sealed later by plastic plugs, tapping them and inserting stainless plugs or simply leave them open, after all it won't rust inside.

Once the chassis has been galvanised you can still drill or weld it if you have to, although welding is better done before galvanising. The sacrificial effect of the galvanising process will protect minor damage or removal of localised areas of zinc, although they are better repaired with zinc rich paint, if only for appearances sake. I look after a Land Rover with a galvanised chassis and it's as good as new after about 20 years of infrequent use. The bulkhead needs welding though!

A couple of links which you may find interesting. There is plenty of info on the net on this subject.

http://www.wedge-galv.co.uk/process.aspx

http://www.youtube.com/watch?v=bd918Kt5r1o&feature=c4-overview&list=UUg8D3vyidzGqUiRTxQ3AyGQ

[scott h]

Re: Restoring my Berlinetta

Thanks for that. Had a look at the links, very informative. I will probably go for galvanising, I know a couple of blacksmith engineers that deal with galvanisers so when the time comes they should keep me right. I wonder what condition the inside of the closed box sections will be, and if they can be cleaned sufficiently for the galvanising to work?

[Robert in Cumbria]

Re: Restoring my Berlinetta

Glad it's some help. The chassis should be sealed, that is the intention of the design, unless there has been some later drilling, the inside will have mill scale and light corrosion, the pickling should take care of that quite easily.

I used to deal with Bunners of Liverpool but they are no longer trading. They used to take painted components, dip them to burn the paint off then pickle them. I had several large gates which had been painted, galvanised that way but I suspect the current environmental regulations will preclude that approach. I would use a large blowtorch and scraper to remove the bulk of the paint and perhaps paint remover and a wire brush to get in awkward corners. The sandblasting route may pile on the expense just to remove the paint, if there is any localised heavy corrosion I would heat it and hammer it to loosen it then the pickling acid will finish the job.

When I was sending a lot of metalwork for galvanising in the early nineties I seem to remember it was about £250 per ton (the weight of the component). I have no idea of the cost now. It can't be too bad because you can buy a brand new hand made galvanised Land Rover chassis for about £1000

[DevinYoung]

Re: Restoring my Berlinetta

Hi just (re)joined the club.
I first built my Berli in the early nineties, chassis No. 1515SBV8. Many of you will know this means it is Sierra based with a Rover V8. Fitting the engine was a
major task not helped by little or no technical back up from the factory. I was told the guy who was developing the V8 installation had left half way through the job! Anyway I solved each problem on my own one by one and my Marlin was registered in Dec 1993. It served as daily transport until 1999 when the call of motorsport won the battle for my time and money! The Marlin was left in the garage unloved and in slow decline, but there is a happy ending because I have rediscovered my enthusiasm for her and a total restoration is underway.
I was never totally happy with the V8. There was not enough room for a big enough radiator and so overheating was a problem. I even tried a second radiator under the boot!Other problems were the brakes. Due to lack of space I relocated the Sierra brake servo and operated it by a home made linkage but I was never happy with it although it passed each MOT. The other thing was low MPG.
So after much thought out goes the V8 and in goes a Vauxhall red top c20xe. I hope this will solve many of the aforementioned problems mainly due to more room in the engine bay, and use of injection and 16v will help the mpg. I hope the performance will be similar as both led lights are about 150hp.
Other things I plan are to sand blast the chassis but I'm unsure whether to paint it or powder coat it or even galvanize it. Any advice appreciated. The standard Sierra rear end will be replaced with one from an XR4 with a viscous diff and disc brakes. I want to fit larger brakes to the front too.
I was a member of the club in the nineties and look forward to being a member again.

it is great such experienced persons are present in the forum but you have not shared any pics. I am excited to see the build

[Mike]

Re: Restoring my Berlinetta

Devin

It is currently being documented under "Build Diaries" - with several photos.

Mike