Berlinetta build and restoration

[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

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

Made a start to removing the front suspension.

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[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

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!

[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

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

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

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[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.

[greyV8pete]

Re: Berlinetta build and restoration

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?

Those top arms look like my Hunter (Cabrio) top arms. As far as I know the top inner bushes are the same as the lower inner TCA bushes. Peter.

[scott h]

Re: Berlinetta build and restoration

Bare chassis.

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[scott h]

Re: Berlinetta build and restoration

Replaced the fuel tank mounting bars with heavier ones, it always niggled me that they were a wee bit light so now I've finally scratched that itch! Unfortunately the local blacksmith did not have exactly what I was looking for, so I cut these bars length ways to get what I wanted using a whole 9 inch disc on the grinder!

Before

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After

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[scott h]

Re: Berlinetta build and restoration

Got back to the Marlin tonight after a few weeks doing other stuff (still involved behind the scenes with oval racing). Turned the chassis over to get good welds on the new gearbox cross member and fuel tank mounts.

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The next job is to drill lots of holes to allow galvanizing. I'm not looking forward to it, seems a shame to put holes in my pride and joy but it is essential to allow trapped air to escape or damage will occur at the high temperature involved. It also allows the inside of any box sections to be treated. I think galvanizing is the ultimate in rust protection so it's a case of cruel to be kind!

[scott h]

Re: Berlinetta build and restoration

Got the afternoon off work and took the chassis to the galvanizer in Glasgow, 2hrs away. They will sandblast it and then galvanize it, should take about a week.

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[scott h]

Re: Berlinetta build and restoration

Got the chassis back from the galvanizer today, it was ready a few days ago but today was the first chance to get the afternoon off work. They sandblasted it then galvanized it and the cost was £264 inc VAT.