Berlinetta build and restoration

[scott h]

Re: Berlinetta build and restoration

Bling bling. A while ago when I came to make a new bulkhead the plan was to replace the aluminium panel with the same, although this time I thought I would paint it rather than leave it bare. However the local blacksmith had no ally in stock and offered me some stainless steel sheet instead. Then a few weeks ago a friend suggested that I panel the front of the scuttle top with stainless, I also made a heater box from stainless. So by accident I had created a theme of having the engine bay shiny. When I needed to buy a fuel swirl pot and a coolant header tank I continued the theme and got polished examples. It now seemed a shame to have a black pedal box, so I got it and the cam belt cover powder coated in chrome effect. I hope to polish the stainless parts.

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[DamnedFrog]

Re: Berlinetta build and restoration

Hello Scott!

Very impressing diary, for sure!

The stainless theme of your engine bay asked me a question for the rebuild of my Roadster...

Since I rebuild my Roadster keeping only fiberglass parts, core mecanic and chassis, I have a total freedom of re-design.

I'll use the service of a laser cutting company near home that, amazingly charges me MORE for AG3 (alu) than 304 (stainless)...

So I'm seriously thinking to a more radical style: everything but the dashboard (safety) could be in 1,5mm stainless riveted sheets instead of 3mm AG3.

I fear a "drum effect" with the engine vibrations because the steel would be thinner and more elastic than AG3, what is opinion on this? All alu or all stainless for the rebuild ?

This is not a question of money, and parts would be laser cut even the hundreds of rivet holes...

Regards,
Christophe.

[scott h]

Re: Berlinetta build and restoration

Hi Christophe, thankyou for the kind words. I can't help you as regards the different properties of stainless compared to ally. Usually there are three main reasons for choosing ally or stainless.
1. Usually stainless is more expensive for a given gauge.
2. Stainless is more difficult to work with.
3. Stainless is heavier for a given gauge.
I would say if price and weight are not an issue and looks are more important then I would go for stainless every time.

[scott h]

Re: Berlinetta build and restoration

Fitted the fuel tank today. After waiting several weeks for someone to weld a mounting flange I gave up and decided to use stainless straps instead. I went for four straps for extra safety.

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The boot floor will hold the tank down, and to hold it from moving sideways I got some special polymer based anti vibration fuel tank mounts.

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You may know them as door stops!

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I will paint the tank with a thick coat of rubber paint or something similar to protect it.

[cameronfurnival]

Re: Berlinetta build and restoration

looking great! Good idea with the bumpstops!

[scott h]

Re: Berlinetta build and restoration

Thanks Cameron. The only problem is that the doors in the house hit the wall now!

[DamnedFrog]

Re: Berlinetta build and restoration

Smart system! In addition, you're ready for e-Berlinetta, with near instant replacement of discharged battery as imagined by Tesla

http://www.zdnet.com/article/watch-teslas-90-second-electric-vehicle-battery-swap-demonstration/

Christophe.

[scott h]

Re: Berlinetta build and restoration

Who will be first with an electric Marlin?

[cameronfurnival]

Re: Berlinetta build and restoration

or electric doors in the house? No need for bump stops then?

[scott h]

Re: Berlinetta build and restoration

It will be easier to sort out the exhaust system sooner rather than later, before the floors and bodywork restrict access. The first thing to tackle is the manifold. The standard manifold is designed for the original transverse orientation of the engine in the front wheel drive Vauxhall. Manifolds to suit rear wheel drive fitments such as Mk11 Escorts are available but obviously cost several hundred pounds, also it would probably need some tweeking to make it fit the Marlin. Among my growing collection of Vauxhall parts are two standard manifolds, so I decided to see if I could make a reasonable job of turning one to fit the new inline fitment of the engine, if not then I would buy one.

The standard manifold.

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Cut in several places.

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The finished article.

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Standard and modified.

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I would like to fit a stainless system this time. There are two places within 15 miles from me that specialize in hand built stainless exhausts so I hope to take the Marlin to one of them soon.

[dcunn]

Re: Berlinetta build and restoration

Good job Scott

[cameronfurnival]

Re: Berlinetta build and restoration

you made that look so easy!

[scott h]

Re: Berlinetta build and restoration

Ha ha. The truth is that I expected it to look like something that had been dragged through a hedge! But I had nothing to loose by having a go.

[scott h]

Re: Berlinetta build and restoration

I took the Marlin to a company called R.J.M. in Glenrothes, who are agents for Powerflow stainless exhausts. I had previously been to speak with them but it is very much how long is a piece of string without seeing the car. We arranged a day to get it done and the plan was rather than me leave the car, I would take a day off work and wait while they made the exhaust. This I thought would be easier taking into account that I had to trailer the car there and I would have to borrow said trailer.

We put the car on the ramp and we discussed what I wanted. When I had the V8 in the Marlin I made the exhaust from universal mild steel parts with essentially a twin system, one on each side of the v8, and ending in twin tail pipes and I liked the look of the twin tail pipes so I wanted the same. I also wanted it on the quieter side so splitting the exhaust would mean a third silencer could be fitted. They set to work and after about an hour there was a huge bang and the electricity went off! It transpires that there was an electrician testing the power supply for insurance purposes and something went wrong, very wrong. The place was at a standstill and eventually after a long wait I went home, not amused but what can you do? Anyway, I left instructions for what I wanted with an emphasis that nothing should be welded to the chassis as it was galvanized, instead they should bolt to the lugs that I had welded in several positions previous to the galvanizing. A couple of days later I returned to collect the Marlin and I was pleased with the result. As the exhaust would be getting removed again I asked for no sealer to be used.

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[cameronfurnival]

Re: Berlinetta build and restoration

very agreeable!