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Mk2 Van project - Engine apart again on Page 44!

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Perhaps an unusual location for a project thread but as it's going to be Gary working his magic to create what should be the ultimate road going van I figure that the best place to show case his talents is in his room.

 

So here it is, bought in December last year and a few of you might have picked up on me asking certain questions about colour schemes, YB set ups or buying up bits and pieces that gave the game I away I was up to something? It's a low mileage (22000) 2 owner mk2 van that hasn't seen the road for about 15 years but will be back with a vengeance later this year.

 

Pics when collected, pretty clean eh? Mint original strut tops too. The close ups of rust bubbles were all that could be seen on a visual corrosion inspection.

 

Plans? Quite a lot really. A YB turbo motor is in build near me at JRE racing engines and Gary's going to work his wonders on the shell in preparation for tubs, arches, big fat wheels and rubber, fostek axle and a turreted linked rear end with coil overs all round.

 

I'm getting excited about driving it already!

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And here it is having gone through the acid dipping process. It's revealed a little more corrosion that will need dealing with, but nothing substantial. All in all, a very sound project basis.

 

The orange stuff that looks like surface rust is fact just dust

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Guest cortinamad-gonetoo

sounds like its gonna be a awsome van when its finished :thumbsup:

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Good project :thumbsup:

 

I liked it with the graphics on... also, if it hasn't seen the road in 15years then why does it have a web address on it?

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Good project :thumbsup:

 

I liked it with the graphics on... also, if it hasn't seen the road in 15years then why does it have a web address on it?

 

That's a good question, I think they had it sign written to be a rolling advertisement for their business but abandoned the plan and left it in storage. I can't check the system for when it was last taxed as the first thing I did when I bought it was make a SORN declaration, I'm pretty sure it was 1993 though.

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excellent project :thumbsup: doesn't look in too bad a state either

 

what are the plans then?

 

Plans? Quite a lot really.

 

A YB turbo motor is in build near me at JRE racing engines and a T5 box, though I can't decide whether to overhall the box before fitting it or just go ahead and install it.

 

Gary's going to work his wonders on the shell in preparation for tubs, arches, big fat wheels and rubber, fostek axle is currently being built with an LSD and 3.75CWP. A turreted linked rear end with coil overs all round and 15" 9J rims with as fatter rubber as I can get. Big brakes, power steering, cleverly designed custom cage with the rear section hidden below a raised floor (about 6" raised)

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Nice one mate ...... I like the idea of the acid dipping :thumbsup: Can't wait to see the progress :thumbsup::thumbsup::thumbsup:

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I like the idea of the acid dipping :thumbsup:

 

Thanks Jo, acid dipping certainly makes light work of getting it back to bare metal and also highlights any corrosion problem areas pretty quickly too. Luckily there isn't much rot to deal with, there'd have been even less if it had been stored a bit better when it was "retired".

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vans FTW! sounds like it's going to be a wicked project! whats the insanly rude looking vehicle behind it up on a ramp in one of the pics near the bottom? looks like it has some split 'superlights' or sumthing with a gold centre?

 

EDIT 6th pic from the bottom!

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oohhh never seen so many posts in here in one day :lol: cheers Scott.

 

The Acid dipping is the dogs danglies, and the orange bloom is just that, you brush it and its gone, the darker orange is parts to be replaced, and then after all work has been done the shell goes back to the dippers for the final dip and E Coating... and its this that prolongs the life of the shell, as every surface is coated, there is no bare metal anywhere, unlike conventional painting. The reason seam rust out is theres no paint in them, even thogh they get smeared with seam sealer the gap 'sweats' and moisture is formed, this then start the rust which bursts the seam, allowing more moisture in, and you have a rusty shell in a few years. With this dipping, the shell should be good for many many years than a shell thats painted. I've looked inside all the cavities that bead/media blasting never reach and its all shiny steel in those.

 

I'm looking forward to doing this one, the brief is a useable car, so allthough it will have race ready suspension it wont be quite like the road/race shells I do... and being a van, i'll be keeping the load space free of tubes. The engine won't be as far back as i normally put them, but i'll pull it back a bit for better weight distribution, the limiting factor here is the doors length, and the vision thats restricted by being a Van.

 

The car on the ramp is a V8 powered escort cossie shell that i'm 6 linking and the wheels are genuine Minilite splits 14"x17"

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oohhh never seen so many posts in here in one day :lol: cheers Scott.

 

The Acid dipping is the dogs danglies, and the orange bloom is just that, you brush it and its gone, the darker orange is parts to be replaced, and then after all work has been done the shell goes back to the dippers for the final dip and E Coating... and its this that prolongs the life of the shell, as every surface is coated, there is no bare metal anywhere, unlike conventional painting. The reason seam rust out is theres no paint in them, even thogh they get smeared with seam sealer the gap 'sweats' and moisture is formed, this then start the rust which bursts the seam, allowing more moisture in, and you have a rusty shell in a few years. With this dipping, the shell should be good for many many years than a shell thats painted. I've looked inside all the cavities that bead/media blasting never reach and its all shiny steel in those.

 

I'm looking forward to doing this one, the brief is a useable car, so allthough it will have race ready suspension it wont be quite like the road/race shells I do... and being a van, i'll be keeping the load space free of tubes. The engine won't be as far back as i normally put them, but i'll pull it back a bit for better weight distribution, the limiting factor here is the doors length, and the vision thats restricted by being a Van.

 

The car on the ramp is a V8 powered escort cossie shell that i'm 6 linking and the wheels are genuine Minilite splits 14"x17"

 

drool 8) escort sounds sick! as does this acid dip process... how much would it roughly cost for a capri (i wont be able to afford it in this year, and probs not the next, but it would be nice to dream!)

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drool 8) escort sounds sick! as does this acid dip process... how much would it roughly cost for a capri (i wont be able to afford it in this year, and probs not the next, but it would be nice to dream!)

 

http://www.surfaceprocessing.co.uk/

 

Give them a call, the process is very very good at stripping and preserving the shell but sadly doesn't come cheap. The initial acid dip was about £900 (inclusive of VAT) but the whole process including the partial redip after works and then ecoating is something like £2500, then you have the cost of transporting it up and down a couple of times.

 

A lot of money but then so is a good repaint and how gutted would you be if rust appeared at the joins 12 months later? I agonised over it for a month or so as I can think of several other ways to spend that money but ultimately decided Gary was right and bit the bullet.

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Hoping to see progress pics and updates on what you have done on a regular basis Gary :thumbsup::thumbsup::thumbsup:

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Axle is all coming together and looking the dogs doodaas! I could weld that neatly once, skills that I shouldn't have let go to waste really but when you've little call to use them for years inevitably they go.

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:lol: Hope you're referring to the Scott rather than the Dick :wink:

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I'm rather pleased with myself for what I consider to be the steal of the century in getting these brand new Avon CR500 245/40/15's for almost half price. Avon wanted a shed load for them so I thought I was going to have to down size my tyre designs, then I found this new set someone had bought and no longer had a use for and snapped them up. Plenty of grippy rubber for me :mrgreen:

 

Perhaps a bit early for buying tyres but I don't believe in looking a gift horse in the mouth, look great on 9J Revo 5 spokes too

 

 

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I'm hoping to see it on the road in 4 - 6 months but that may be a little optimistic

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