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Thread: Stu's Mk3 Capri project

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Stu's Mk3 Capri project

    Welcome to my Mk3 , a 1980 2.0GL with 51k on the clock...



    Having picked up this little beauty last weekend as a spare car plaything, I've built up a small list of goals that I want to achieve with it;
    1. Get an M.O.T.
    2. Give it a full service and learn what all the oily bits are for
    3. Fix essentials, such as brakes, suspension, rear wiper
    4. Stop the rust that's eating away at it and spruce up the bodywork a little
    5. Get out and have fun in it
    I've made sure to get this list in first so that six months down the line folks can mercilessly remind me how low I set my sights

    At the moment, my ground rules are that the car must remain moveable with two weeks notice (due to an impending house move), money is an object and the car should stay close-ish to standard (enough to convince my darling girlfriend, at least ).

    The main problem I've got is that I've spent most of the last twenty years throwing the keys to the chap at the garage to deal with any problems, so I'm starting from the position of not really knowing anything. I learnt to gas weld at college (before dropping out after 3 months), but that's about it. I'll readily admit that I know stuff all, so please excuse what might at times be some glaringly obvious questions

    Onwards and upwards then. Having checked the basics on the car before setting off, I drove it straight down to the MOT centre to see whether I'd got a lemon or a peach.


    Almost, but not quite ... failed on wipers, headlight aim and two small holes in the offside sill just level with the front spring hanger. At least the tester was a nice chap into Morris Minors who happily put it back on the ramps and showed me "how nice and solid it was underneath". He said he'd want to see it come back with a seam welded patch to the sill - nothing fancy...



    On the basis that I'm scuppered without an MOT, I got in touch with a local young surf-dude type via the power of Google and a VW camper forum, and he's coming round this week to get it sorted.

    Whilst waiting for various engine service bits to arrive in stock at the motor factors, I've made a start at the rear end and discovered where the previous owner used to keep his fish



    So, first questions that spring to mind are;
    • what did the three discs in the wheel well used to be, and are they important, as the Haynes doesn't hint ?
    • what's the best plan of action for now ? Clean down to bare metal, rust treatment then primer ?
    • there's a couple of small holes arrowed - is the floor double-skinned here or did my scraper hit the top of the petrol tank ?

    Out for a drive on a sunny spring day reminds me why I got this car

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    Well, to answer one of my own questions, the discs are the drain plugs for the wheel well, which, for reasons best known to Ford are metal. Quite why you'd put a metal plug in a metal hole in a bath of water and then expect your customer to remember to pull the plug out just once in 26 years ...

    Alex The Welder came round this afternoon and patched up the sill that Mr MOT wasn't happy with.



    Must say, it looks mighty fine to me

    Anyone wanting some welding doing in the Preston area should consider giving Alex a call on 07760288250, if only to see him turn up in what I understand is the lowest bay window camper in the country

    Last edited by Stu.C; 12-10-2006 at 19:23.

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    Good luck with the project, mots are allways grief and like the campers well smart

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project





    Woohoo, it's passed second time round

    Mr MOT had a look at the welding and said "Oh, that's nice to see, that is. Proper old-timer's welding - you don't see much of that nowadays." It was nice to be able to tell him that the chap who'd done it was (at most) half his age.

    Next task for this weekend is clean up the engine bay, try and keep the oil inside the oily bits and flush out the coolant - from looking under the rad cap, he seems to have used Rowntree's Lime Jelly instead of anti-freeze

    Out for a drive on a sunny spring day reminds me why I got this car

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    Well, it's always the way - get a new toy, spend more time at work instead of playing with the toy

    Anyways, to catch up on what's happened since last time, I've;
    • discovered that the local motor factors are useless - wrong rotor arm, condenser and rocker seal
    • gunked the engine - will need another couple of go's I think
    • changed the oil, filter, plugs, etc.
    • flushed out the coolant & backflushed the rad
    • replaced the ignition consumables and set all of their gaps (amazing how far out some of them were!)
    • bought proper tools to replace some Christmas-cracker style ones I'd got a few years ago
    • secured the loan of a mig welder from a chap at work's brother
    On Sunday, it started off quite bright, so I rolled her out of the garage and took advantage of the sun coming out for a split second.



    Working my way round each corner, I wanted to see what the state of the brakes and suspension was and was amazed (given the way some other areas have been "left" by the previous owner) to discover that there's more than a month's life in the discs and pads! What wasn't so impressive was the two and a half tons of topsoil I found in the crevices behind each wheel.



    Considering how much soil was in here doing nothing but retaining moisture and rotting the panels, I'm surprised there's no wheelarch liner for these cars, or maybe there should be and it's already rotted away ?



    Got home from work last night all keen and opened up the rocker box to take a look at the oily bits.



    Clearances seem to be a way out from the Haynes on some of them, but quickly realised I'd need a bendy spanner of some sorts to get at some of the nuts, so I'll see what I can pick up tomorrow. Spray bar is downstairs soaking in white spirit and the cover's waiting to be gunked.

    One thing that occurred to me though, should all the rocker box bolts have the same washers? Some were the split type, some were solid and graunched where they'd been forced to take the thread and some had seemingly attached themselves to the cover ...

    Out for a drive on a sunny spring day reminds me why I got this car

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    Well, to follow up from my last post first, after chatting to a chappy from the Capri Club International at the Classic Motorshow this weekend, it turns out that later Mk3's were fitted with front arch panels to stop the wing filling up with debris ... and conveniently CCI sell a repro for 42 quid for the pair. Looks like I'll be getting a set, unless anyone knows of a cheaper source ?

    I'm sure I should have bought more stuff while I was there, but given I don't really know what I need to be doing, it seemed pointless buying up every gadget and gizmo just cos' it was 50p off. Did pick up a set of Goodridge hoses though, for when I get round to refubing the calipers (oh, I see CCI do a caliper refurb kit too!).


    Managed to get back out to the garage tonight, and having set the valve clearances per the book (0.2mm inlet, 0.25mm exhaust), refitted and checked the spray bar and refitted the freshened-up rocker cover with a new gasket I fired it up to check I'd still got a working car. Nothing Worked my way back round everything I'd been fiddling with and discovered that I'd dislodged the wire going from the suppressor(?) on the condenser back to the coil whilst hand-cranking the engine. Finished following the ignition path round, found nothing else, so tried firing again and it sprung into life OK, so I know it's not exactly rocket science, but two weeks ago I knew bugger all about what happened after I turned the key

    Next, I moved round to the carb which looks to be in serious need of a clean up, if not an overhaul.



    My enthusiasm for taking the carb apart is, of course, in no way related to having made a cheapy book find at the show



    With the engine running, I gave a few short squirts of carb cleaner to the choke flaps to which the engine responded by stuttering momentarily and throwing smoke out the exhaust. Pretty much as expected, I believe. I was about to set to with the cleaner round the outside of the carb when I noticed a definite drip running off the brass nut under the fuel intake Switched off, checked the nut for tightness, then checked the little filter and all was clear. It was at this point I noticed there's a small split in the end of the fuel line coming from the pump, and once I'd got a good light down there I discovered the whole area's covered in a sticky yellow goo which I assume to be old fuel, so I'm guessing it's been leaking for a while. At least it's probably not dangerous to have fuel squirting out into a hot engine bay percypercy:

    With not having a fire extinguisher in the garage yet, I decided to call it a night and slunk back indoors for a cuppa. Given that those fuel lines are getting on a bit, I think I'll replace them all as I can't say I've got much confidence in 'em at the minute. Off to the interweb then to find a supplier ...

    Out for a drive on a sunny spring day reminds me why I got this car

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    What curb ;-) Decade Plus User FF_Mark's Avatar

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    Re: Stu's Mk3 Capri project

    Doing some great work there, nice to see another Capri on here too.

    Keep up the good work and keep posting updates.

    I can't wait to get some time to spend on mine.
    Cupra Formentor / MR2 Mk3 / Fiat Ambulance

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    Re: Stu's Mk3 Capri project

    I somehow failed to see this thread. Sorry about that mate, it looks like you have been talking to yourself for a while.
    Looking very good so far.
    Fuel pipe is available off the shelf from Halfords, or your local autofactors.
    Autofactors are usually cheapest, but Halfords are open at convenient times. There are various sizes sore measure before you buy.
    The bendy spanner you need is a valve setting tool, there's usually one or two on ebay for small money. Make sure you get one for a pinto. (Just had a look but can't see one) I've got one if you are desperate.
    If the front calipers need overhauling it makes more sense (to me anyway) to get some refurbed ones from a local factor. Roughly 40 each, and an excellent opportunity to replace those rubber flexi's, and the brake fluid. Just use ordinary fluid.
    Personally unless the carb is seriously playing up, I wouldn't be in too much of rush to dismantle it. If you do, make sure you have a full service kit for it first, available from Burtons.

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    6mm internal diameter for the fuel hose ? Can't be too careful, as the local factors seem lost with anything unconnected with Saxos and Corsas.

    Is a separate inline fuel filter worthwhile for a standard engine, would you say, or more of a cosmetic affectation, given that anything will have had to come past the one in the pump anyway ?

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    Is there one in the pump?
    It won't do any harm

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    Re: Stu's Mk3 Capri project

    Quote Originally Posted by Stu.C View Post

    Is a separate inline fuel filter worthwhile for a standard engine, would you say, or more of a cosmetic affectation, given that anything will have had to come past the one in the pump anyway ?
    i think your find the fuel hose is 8mm

    fitting a filter wont do any harm, although i've often seen percy: go through those cheapy plastic inline jobbies.

    as dave said i personally would leave the carb alone unless its playing up, those DGAV's are incredably reliable and need very little attension, many a carb has been spoilt by an unnecasary rebuild in in experienced hands, not saying you would damage it stu, but here i thinks its a definate case of its if aint broke dont fix it.
    Last edited by Graham; 01-11-2006 at 09:44.

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    Thanks for clarification on the fuel hose, Graham.

    as dave said i personally would leave the carb alone unless its playing up, those DGAV's are incredably reliable and need very little attension, many a carb has been spoilt by an unnecasary rebuild in in experienced hands
    I'm more than happy to take advise from those who know better, especially as I lost the will to live whilst reading somewhere around step 34 of the disassembly instructions over breakfast The book's still a good buy though, as the background chapters are fascinating reading - respect to Weber and their boffins

    I'm seeing a pattern emerge now though, where my mindset's still of the "if it's dirty, there must be something wrong with it" tendency ... fine for the Impreza, but a culture shock when I get to the Capri

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    Quote Originally Posted by Stu.C View Post

    I'm seeing a pattern emerge now though, where my mindset's still of the "if it's dirty, there must be something wrong with it" tendency ... fine for the Impreza, but a culture shock when I get to the Capri
    I call it "patina"

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    Whilst sitting in a none too interesting meeting this afternoon , my mind wandered back to the leaking fuel pipe and the fact that it's the left-side hose that's leaking - which I think is the fuel return to the tank.

    Given that the pump is pushing stuff through the inlet side as fast as it can, and any excess that's not fed down the carb goes out the return pipe, would the fact that it's leaking out of the connector (as you can see in the pic above) suggest that maybe there's a blockage in the return pipe ?

    I'm 150 miles away from the car at the minute, so checking this will have to wait until I get back on Sunday, but I thought I'd ask anyway

    Out for a drive on a sunny spring day reminds me why I got this car

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    Way too much free time Decade Plus User PIG's Avatar

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    Re: Stu's Mk3 Capri project

    keep it up m8,good to see you having a go your self m8,keep us posted to how its going tho ,clean looking car tho bud

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    Re: Stu's Mk3 Capri project

    Replace the pipe and see. It is probably perished and just weeping.
    The bit you are replacing is about a foot long (ish). It's rubber from the carb then changes to plastic (smaller bore)
    There is a possibility that the plastic return has been squashed flat at sometime when the car has been jacked up. Have a check under the car where the pipe runs along the chassis.

    I wouldn't want to contradict Graham, but I have seen return pipes smaller than the feed. Check with a measure.

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    Re: Stu's Mk3 Capri project

    If the cars been using unleaded it will probably have rotted the rubber hoses may as well do both while your at it

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    It's nice when there's stuff in the post that's not bills, Sky TV offers or yet another ransom note for the ex-girlfriend ...



    One Filter King (a combined fuel filter and pressure regulator) and a couple of metres of 8mm braided fuel hose.

    After jacking the front end of the car to give me good access all round, I decided on the rear of the inner wing for mounting the filter, based upon the combined might of looking at a couple of pictures on the internet and the fact that there was empty space there Marked up, drilled through, put some cork underneath the mounting plate to stop any abrasion, bolted up and sprayed some Waxoyl inside the wheel well.



    Next, I worked my way round each hose replacing one at a time, especially enjoying replacing those wierd spring clamp thingines with some nice band clamps.



    After turning over a couple of times, the filter was half full, so I was ready to fire up the engine to test, but had to pop back into the house to get the defibrillator as I'd killed the battery After hooking it up, I turned the key, the engine spluttered into life and nothing leaked It's a bit wierd actually seeing the fuel swirling around in the filter - but better that than have it squirting out of the old hoses.

    Flushed with my success, I opened up the boot and deployed the official Turbosport rust/paint remover which revealed that pretty much the whole bottom of the well is full of small holes from where the water's been sitting for years.



    Given that fixing up anything down here will require removing the tank, my plan is to leave that for now and just give it the once over with Kurust then spray on some primer.

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    Nice work, you going for concours with the colour coded blue pipework eh

    looks a nice tidy install though

    And as for the well that looks pretty mint to me but i dont agree with you wanting to leave it and come back with some kurust and primer....im sure dave roberts would agree here, what you want to do is put the wheel back in it so you cant see it therefore making it appear to have vanished

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    Re: Stu's Mk3 Capri project

    Nice one Stu It's coming along nicely

    Great to see you asking questions, taking it all in & learning as you go

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    Re: Stu's Mk3 Capri project

    get some form of paint over the primer even for the time being... primer is a porous paint and will soak up any moisture in the future so get it paintedelse your primer will start to turn orange.
    good to see it coming along.

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    Thanks for all the encouragement guys It's funny that if I'd tried this a few years ago, there would have been no Interweb to help me out and I'd probably have either jacked it in in frustration or paid a garage to do it all.

    Certainly not going for a concours job Dave, but must confess I do like a little bit of tartiness under the bonnet

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    This is evident you tart

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    Re: Stu's Mk3 Capri project

    whats next on the list stu? theres always something lol.
    pauly

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    Next on the list should have been a weekend of working on the car, but I ended up spending it driving a Transit to Newcastle twice and filling it up with house bits

    When I get the chance though, the next thing on the list will involve playing with a Mig welder



    I learnt to gas weld years ago, but that was always on the understanding that the student's would be going down the road to build ships at Camell Lairds, so thin car panels are an unknown to me. Popped down to the local steel stockholders last week and had a rummage in the skip whilst chatting to their warehouseman and came away with a load of offcuts in various thicknesses to try my hand at.

    To give me some more practice before trashing the Capri, I also picked up an early Sierra wing from a local breakers so I can cut out and replace sections and easily check both sides of the weld.



    It seems a shame to trash an unused panel like that, but the breaker assured me they were ten a penny ...

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    fair play, good idea. exactly the same welder as i use.
    sure you'l pick it up again quick enough.

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    Re: Stu's Mk3 Capri project

    Looks nice and shiny

    And the inner wing if genuine ford i wouldnt have thought is all that common, if it was only a few quid i might try it up on ebay and see if you get some money for it???

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    Pit Crew Turbosport Subscriber Stu.C's Avatar

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    Re: Stu's Mk3 Capri project

    Yikes Just found this one on eBay that looks to be the opposite side for a BuyItNow of 95 quid !!

    Given the one I've got in the garage seemed to be unused and still has the Ford parts labels on it, I think I'll canvas further opinions before chopping it up.

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    Copy his ad and link to it, this is the matching r/h inner wing for your cosworth resto buy it now 90 then buy some sheet steel

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    Re: Stu's Mk3 Capri project

    and get back down to wherever you got it from and see if they have more lol. if they do buy the lot!

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    Re: Stu's Mk3 Capri project

    Well, today didn't turn out quite how I expected, which seems to be par for the course at the moment Yesterday's viewing of a house with a "detatched double garage" turned out to be a pokey workshop where the front wall was made of breezeblocks with fake doors screwed on the outside

    Started off with some general beads to get a feel for the welder and playing about with the wire speed, listening for sizzle and adjusting the power to see what's what;



    On the left is the front and the reverse side is on the right (mirrored in Photoshop). I then decided to get all organised and work my way up through all the power settings running a bead for each to use as a reference, so I grabbed a fresh 1.5mm sheet and set to...



    Unfortunately, as soon as I set the power to 5 it tripped the circuit for the garage. And then it did it again. And again Game over for today on the welding then, as I need to get myself a nice heavy-duty extension lead to run from the oven socket in the kitchen. Turns out that novel-writing girlfriends aren't amused when the power goes unexpectedly

    Lacking the willpower to face B&Q on a Sunday afternoon, I attacked the rear valance with the rust remover pad on the grinder, applied Kurust, sanded it back down and then gave it a couple of coats of zinc primer. Went from this ...



    ... to this ...



    Which makes me think that I might just as well get a whole replacement panel and do that at the same time as both lower rear corners and the bottom of the wheel well.

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    sounds like a better idea stu. good to see your cracking on with the welding..... looking pretty good too!!
    keep it up mate

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    Way too much free time Decade Plus User PIG's Avatar

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    Re: Stu's Mk3 Capri project

    good to see you still keeping at it m8,good work buddy

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    Re: Stu's Mk3 Capri project

    If youve never welded before, it looks like you were born to!! Thats bloody good if you have never picked one up before

    And from them i would say row 2 runs 3,4 & 5 are the ones you want, nice and neat both sides with lots of penetration

    Think i might have to do similar to get to grips with my new welder

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    Re: Stu's Mk3 Capri project

    Good work mate.
    I find 1.2 sheet is easier to work with, 1.5 is hard to bend.

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    Re: Stu's Mk3 Capri project

    Rather annoyingly, I'm getting home from work too late at the moment to start cutting up bits of metal to practice with the welding ... especially as the garage shares a wall with next door's lounge

    To not lose momentum, last night I started to take apart the front end of the car to guage how much work was needed here.



    The bolts on the outer bumper brackets didn't want to shift for love nor money, so I've drenched them in Plusgas and will try again later. The front valance doesn't look too shabby and should clean up alright, but I'm thinking more and more that new front wings will be needed.

    Next concern is the headlamp bowls; both have a fair bit of deep rust and the offside has escalated to actual holes, but what I can't work out at the moment is what tool I should use to get them back down to bare metal - the angle grinder doesn't seem to fit





    The area around the headlamp inspection panels is flakey on both sides, but looks like it should clean up and be treatable at the minute. Having said that, it's probably one of those areas that's a sandwich of five layers of metal and will need more work than I expect




    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    Looking good
    And i would use a wire brush attachment on the grinder and /or drill to get in them headlight bowls.
    Dont be afraid to push the grinder in ther hard just make sure you wear gloves and hold on tight

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    Re: Stu's Mk3 Capri project

    looking good stu.... keep it going.
    neighbours wont mind??????????????? lol

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    Re: Stu's Mk3 Capri project

    Headlamp bowls now dealt with, for the moment, at least until I've got better access when I replace the front wings (did anyone say "scope creep" ??? ).

    Cleaned them out with a variety of brass cups and flap wheels in the drill (gotta admit I basically just got one of everything and kept trying each one to see what happened) ...



    ... then applied the magic rust killer ...



    ... and gave it a couple of squirts of zinc primer



    Now I need to find a good local fastener merchant to get me a jumbo-sized jar of stainless bolts, sets and self-tappers in assorted sizes. I'm picturing something like an old-fashioned sweetshop with shelf after shelf of glass jars, and I ask for a couple of bags of "Mk3 Capri - mixed" Don't suppose it's that simple though, so if anyone can suggest any good online variety pack suppliers it'd be most appreciated.

    Out for a drive on a sunny spring day reminds me why I got this car

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    Re: Stu's Mk3 Capri project

    How about screw fix?

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