P66 Progress Update

[Han Kamp]

Derek, you leave us speechless........

[DerekCV8]

Have spent weeks (probably months?) trying to figure out how to repair the P66 dashboard..... but think I've finally solved it!! The dashboard is an "ABS" (or possibly "Styrene") moulding and showed signs of deterioration, the worst being a complete break around the glove compartment. It cannot be reinforced on the rear surface due to the way it mounts on it's supporting bar, so I had to figure a way of strengthening it from the front. The ABS is about 2mm thick, and my first thought was to try and model a new dashboard in steel....... silly idea..... it would weigh a ton!! So, next idea was to try and laminate a thin (1mm) sheet of aluminium to the front. I started work on this and it "might" have worked ok, but would have been a difficult task to get the aluminium to the right shape...... and would not have added strength to the contoured areas...... so it was back to the drawing board. I then decided it would be worth trying to laminate the front surface with fibreglass..... but would this melt the ABS?? A test area proved it wouldn't, but after some research online, I found that there can be a problem getting the resin to bond to the ABS and it may, eventually, delaminate? However, whilst searching online, I found the answer!! I had already planned to use glassfibre tissue and it was suggested to use a solvent that's aggressive to ABS to initially bond the tissue to the surface, followed by the resin. From my model flying days, I knew that "Solarlac Thinners" (available from all good model shops!) could be used to soften ABS (We used to use it to join two halves of ABS RC Aircraft cowls). I had some of this in my workshop, so decided to give it a go. The result.... it works PERFECT!!It softens the ABS just enough to bond the tissue to it with amazing strength before it evaporates and hardens again. In fact, you can't remove it again without sanding it off!! I've now almost finished covering the entire outer surface with the tissue and it conforms well to the compound curves. Even without the resin added yet, the whole structure feels more solid. The picture below was taken just after I got the main pieces in place. All apertures are now opened up. Tomorrow, I will finish off a little more work bonding the tissue, then start with the resin, so further pictures will follow! The front of the dashboard is covered with a thin foam, so has a little flexibility regarding thickness to allow this method of repair. The next problem will be covering it, as the original covering was not black vinyl, but another vacuum formed moulding!!! Jensen did like trying new things!! I'm hoping I can find a black vinyl that will be flexible enough to work into all the instrument cowls...... we shall see..... but a few choice words may be muttered!!

[jglarkin]

Fantastic when a plan comes together. I do like a bit of Dun It Yourself.

[DerekCV8]

Fitted the Brake Servo & Rocket launcher today.......



..ok.... it's really the heater trunking.....



The reconditioned servo and brake master cylinder are up to Classicar Automotive's usual standard (the sticker is available on ebay!)....



Need to get this all fitted first as access once the wings are back on is virtually impossible!....

[Mark1Stu]

Fantastic work Derek.

[RAP72]

That's looking the dogs dangly bits.

[felixkk]

looks excellent!

[DerekCV8]

Front section and Drivers side wing now fitted......... having a break away next week, then big push to get the engine and transmission back in......

[Jens]

Stick, cable and plug still there, what happened to the ladder?

(Reminds me of "The Draughtsman's Contract")

[DerekCV8]

Had to move the ladder to be able to open the door…. to get to some of the wing bolts! Progress doesn't look too much comparing the pictures….. but lots of "hidden" jobs had to be done before I refitted the wing.

Will look better when I get the engine back in!

[Martin R]

Will look better when I get the engine back in!

I think you mean "even better"
Fantastic job

[colin7673]

I said your be 'on the road' before me Derek

[DerekCV8]

Had to remove the rear seats of the P66 today to gain access to fit a new fuel line. In the process, I came across repairs carried out to one of the "cubby locker" interior parts by Jensen Parts & Service..........



During the work to repair rusted areas on the front end, I also found that they had simply folded the rusty metal inside, then welded a plate over the top, leaving all the rust there!! Needless to say, I have now completed these repairs properly.

It never ceases to anger me that people who claim to be "professionals" and to whom we trust our pride & joy, can carry out such shoddy work. It's no surprise that they are no longer in business? Good riddance I say......

[colin7673]

It never ceases to anger me that people who claim to be "professionals" and to whom we trust our pride & joy, can carry out such shoddy work. It's no surprise that they are no longer in business?

I have to agree here, this is why I'm having to do so much to our car as we paid good money to have something done correctly and only half a job was done.

[Joerg]

I strong believe in DO IT YOURSELF or under your closest control - because every company working on a car is under economic pressure as long as the customer does not have an unlimited budget (and than it is not economic for the customer).
Have seen too much sh... from professionals (even on everyday cars).

Joerg