Berlinetta build and restoration

[listerjp2]

Re: Berlinetta build and restoration

After removing all those bits I think the garage floor needs a sweeping. Make sure you keep the metal it might come in use - Man flu it gets us all.

[scott h]

Re: Berlinetta build and restoration

Rear suspension came off next. The whole rear end from the Sierra is used, unlike the Sierra based Cabrio.

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[scott h]

Re: Berlinetta build and restoration

Back in the real world I removed the rest of the front suspension. Most of the bolts came off ok, after 20 years a good advert for copper anti seize! The nuts on the end of the anti roll bar required a more agricultural approach though.

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Job done, only thing is separating the TCA from the anti roll bar, the bushes are stuck fast.

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I can't remember what the rubber bushes in the top wishbone are. I think they are the same as the Cabrio. Are they Cortina rear suspension bushes? Any ideas?

[scott h]

Re: Berlinetta build and restoration

Last week I was suffering with double pneumonia, ok maybe just a cold, but it stopped me from going out to the garage. I was still thinking about the Marlin though, and spent a couple of evenings reading this M.O.C. forum, it was a choice between that and watching third rate celebs in the jungle! Anyway, to cut a long story short one subject fired my imagination, power steering. I had heard of Mk2 Escort rally cars fitted with the electric unit from a Vauxhall Corsa, but it wasn't until I studied how Lee and Mike went about fitting the same unit to their Cabrios that I wondered if it would fit the Berly. A quick search on Ebay and I found numerous Corsa units for sale at £40 which was cheaper than I expected so I clicked buy it now.

The unit is quite large, here it is next to the Sierra column.

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I pulled it apart.

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But there is just no room to fit it in the foot well. Here it is on top of the pedal box.

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This pic shows how the Sierra column fits through the bulkhead and pedal box, not much room to spare.

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The only option is to fit it in the engine bay, replacing this short shaft.

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It could be done but it may compete for space with the standard Sierra brake servo that I am determined to fit. I think I will put it on the back burner for now. Back in the 1990's when I last used the Berly the steering was never an issue and maybe I should just forget it? What do you guys think? Is the steering an issue?

[scott h]

Re: Berlinetta build and restoration

Thanks for the encouragement Adrian, I need all the motivation I can get to go out to the garage on a cold dark winter night!

[listerjp2]

Re: Berlinetta build and restoration

Keep it coming Scott, we really love this stuff no matter what the Marlin Make. Adrian

[scott h]

Re: Berlinetta build and restoration

Made a start to removing the front suspension.

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[scott h]

Re: Berlinetta build and restoration

Four core radiator based on a black taxi unit and brackets made from folded galvanized sheet.

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When I made the brackets I had in mind the need to block air escaping around the sides of the radiator.

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I mounted the rad as high as possible to try to avoid air locks. I hope to just fit an expansion tank with no need for swirl pot etc, fingers crossed!

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The next job is to lift the engine and gearbox out then strip the suspension.

[scott h]

Re: Berlinetta build and restoration

I like to try to do at least one job on the Marlin each day, even if it's a small thing, otherwise I feel lazy. So tonights half hour was spent taking the steering column off.

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[scott h]

Re: Berlinetta build and restoration

My search for a suitable radiator has come full circle, after a few enquiries I have decided to get a Taxi type of radiator made. Richard at Cooling Solutions (01205355016) can make any size of radiator to order but has a batch of parts to make four core rads to the same size as my old one, slightly thicker due to the extra core. His advice was that it should easily cope with keeping the red top cool, but was able to make a larger one if I really wanted, this would take longer and cost more.

As the plan is to galvanise the chassis I am trying to think of any brackets that may need to be welded on and do it now, hence the radiator at this stage of the restoration. The engine was fitted with an oil cooler so I wanted to get one mounted now aswell. However after searching the web I was unsure what was required so I called SBD motorsport who are experts in, among other things, all you need to convert the Vauxhall red top to rear wheel drive. They advised me that an oil cooler was probably not required as the sump is far more exposed to the cooling air flow than in the donor car. They suggested that I fit an oil temp gauge just to be sure. I think I will weld lugs to the chassis which can be used as a foundation to mount an oil cooler without welding once the car is on the road.

[scott h]

Re: Berlinetta build and restoration

Pedal box came out next.

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Then the under dash wiring and column switches, hope I can remember how to put it back!

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[scott h]

Re: Berlinetta build and restoration

I remembered that I had this old radiator left from when I raced stock cars.

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It's a three core unit that is originally found in a black taxi, it is the radiator of choice for most stock cars and they have around 180hp so should be up to the job of cooling the 150hp red top. It fits with room to spare, about 70mm on the width. So the plan is to get one made but maybe 50mm wider so that should easily keep things cool. I have been recommended to try a company in Dundee, so watch this space.

I also removed the scuttle top / bulkhead ( or whatever you call it ). I obviously didn't take any chances that it would leak during the original build, it was stuck fast with plenty of sealer!

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[scott h]

Re: Berlinetta build and restoration

Thanks for the tip on the radiator David, I will have a look at the website.

[dave_clutterbuck]

Re: Berlinetta build and restoration

Hi Scott
Andrew Cropper 0151 327 2560 at Cropper & Jones maybe able to help with your radiator
Web site is www.radiatorrepairs.co.uk
He did a couple of fuel tanks for me, he told me they can make radiators.
Regards
Dave

Finally I got back in the garage after a busy couple of months doing the harvest on the farm. I removed the windscreen and didn't even break it, which was nice!

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I also sat the engine and gearbox in position so that I could measure up for a radiator.

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So the search is on to find someone that can make a radiator to my measurements.

[scott h]

Re: Berlinetta build and restoration

It does look good in the engine bay Cameron, unfortunately this one is a non runner as the timing belt snapped. But it was cheap and I reasoned that with this engine being out of production for a number of years, even one that was running will be of an age and mileage that a rebuild would be in order anyway. I keep looking on Ebay for a good low mileage Red Top though, so the engine rebuild will be one of the last parts of the restoration of the Berli.