GavinR's Mk2 Rally Car - FLY

[mexicotait]

Found this gav
Dust is a bit extreme !!

[mario r h santos]

Re: GavinR's Mk2 Rally Car - FLY

Congratulations Gav.

Nice work!

Keep it up.

Cheers,

Mário Santos.

[Arwel]

Re: GavinR's Mk2 Rally Car - FLY

[ATTACH]58927[/ATTACH]

Found this gav
Dust is a bit extreme !!

Wooo Claire wont be happy that her pic has been cropped like that... Thats from Classic Tracks on the first test. Good effor that day Gavin.

[mexicotait]

Re: GavinR's Mk2 Rally Car - FLY

It was on face book like that
Hope the author doesnt mind
They were all great photos

[GavinR]

Re: GavinR's Mk2 Rally Car - FLY

After Neath Valley, the rear arches were looking very bad, they'd split away from the inner arches and were rusting out from the inside. Although I do as much maintenance as possible myself on Fly, I didn't fancy tackling the arches, so I phoned Oddy from South West Resto's and arranged to take Fly down one evening so he could have a look at the work required

So 3 weeks ago I drove Fly to work and then on to Oddy's afterwards, we had a good look round and agreed what needed doing. On the way home, a few minutes from his workshop, I pulled up at a junction but unfortunately an elderly gentlemen following me didn't realise I'd stopped and drove into the back of Fly
First on the scene was Oddy, so I asked him to do a quote for a new rear panel, and swapped details with the other chap

It seemed a gentle tap, but went in at least 6 inches. Luckily it was near the middle, so the chassis rails are fine


Pulled the boot lid in slightly


I'm glad I've got a stick on number plate


Inside, back panel rather bent


Floor slightly kinked


Shiny marks on the tank are where the spare tyres got pushed into it. No dents or leaks though


Cracked the rear light housing


Split from one corner as well


So not a good trip, but the gentleman was very apologetic

[GavinR]

Re: GavinR's Mk2 Rally Car - FLY

I don't have time to wait for insurance companies, and needed to use Fly as Course Car on the Exmoor Endurance Rally which ran on 6th October, so the weekend after the accident, I set to work with the Portapower

Using the tank mounts and the internal panhard rod brace as solid parts to push against, it took me an hour to get to this stage, didn't use the hammer once and the paint is still good

Outside looking good




Inside needs a bit of welding, but it will do for the moment


Spare bumper fitted but the same rear light, melted the cracks together with a soldering iron


Good as new, almost


Course Car duties went well, despite the starter motor disintegrating early on, luckily there are plenty of hills around Exmoor so I bump started her all day as needed

[oddy]

Re: GavinR's Mk2 Rally Car - FLY

Gavin,
would you like a job? Apologies again!
Cheers,
James

[trig]

Re: GavinR's Mk2 Rally Car - FLY

Was gona say the same thing bud lol.

Make shore the insurance pay out for what you want done bud just if you have half repaired it they may say its repairable now.

[GavinR]

Re: GavinR's Mk2 Rally Car - FLY

Progress report from Oddy

Paint ground back to show where the previous arch was welded on


All cut away


New arch welded on


Inner arch tubbed for clearance


Welds ground back and lip folded up


Skim of filler to blend it in


Looking good

[Paul C]

Re: GavinR's Mk2 Rally Car - FLY

Excellent Gavin, What was the out come with the insurance pay out/ claim?

Not long till mine has a trip to WSM!

[stuartf]

Re: GavinR's Mk2 Rally Car - FLY

I passed you on the A42 on Sunday morning on my way back from Donington. Brightened my morning.

[GavinR]

Re: GavinR's Mk2 Rally Car - FLY

Some in car from Neath Valley Stages back in August

Neath Valley Stages 2012 SS1

Neath Valley Stages 2012 SS2

Neath Valley Stages 2012 SS3

Neath Valley Stages 2012 SS4

Neath Valley Stages 2012 SS5

Neath Valley Stages 2012 SS6

[mexicotait]

Re: GavinR's Mk2 Rally Car - FLY

Any more progress gav
Im liking the idea of the tubs

[danknight72]

Re: GavinR's Mk2 Rally Car - FLY

Great vids Gavin,looks rough as fook
in there though

[GavinR]

Re: GavinR's Mk2 Rally Car - FLY

I got Fly back at the end of October, which left me a week to get her back together for the next road rally

The other arch was very similar and Oddy finished off with filler both sides and a coat of primer




Back in my workshop, masked up and some more primer




A few hours later, top coats of Signal Yellow




It wasn't particularly smooth and didn't quite match the rest but it was definitely Yellow

So all that was left was to put the interior back together and then on the Thursday night I had a look at the starter which had failed on the last outing. I was assuming the cog had come off the end as it still span but didn't engage with the engine. Took it out and it looked perfect
Reached inside the bellhousing to check the ring gear and found it wasn't attached to the flywheel anymore

Friday night, removed the gearbox, clutch, flywheel and ring gear (luckily it was undamaged). I had hoped to get my landlord to heat it up with his oxy-acetylene torch but he'd gone away for the weekend, so I stuck the ring gear in the oven for 30mins, took it out and it dropped straight on





Let everything cool down then back to the workshop to refit everything and she was running by midnight