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Interceptor bodyshell/chassis built from scratch

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by Martin R » Wed Dec 11, 2019 12:17 am

Chris_R wrote:And this is how Jensen dipped the cars.

It didn't appear to help in stopping the rust though did it?....
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by Chris_R » Wed Dec 11, 2019 1:38 am

Martin R wrote:
Chris_R wrote:And this is how Jensen dipped the cars.

It didn't appear to help in stopping the rust though did it?....

No, it didn't.
The bodyshell was first dipped in an acid wash to remove all trace of grease and then lowered into what was described as "a huge bubbling cauldron of brown primer paint". Four gallons of the five-and-a-half thousand in the tank stayed on the car.
Next after being wiped clean and drying the car would have been sprayed with several coats of red primer.

But I think rust prevention was still rather in its infancy at that time but at least they tried. In the '60s and '70s and even into the '80s it was quite common to see cars only a few years old with rust appearing. Contrast that to these days when it's rare to see even a 15 year old car with rust. Body design and materials and rust prevention are much more advanced now than they were then.
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by Joe Schiavone » Wed Dec 11, 2019 4:34 pm

Back in the 70’s Chevy Blazers roofs used to rust out because an air bubble would exist in the roof area not allowing primer to coat all the metal in the dip system so they switched to the electrical system which could stop at a predetermined thickness In today’s restoration shops need to use pressure systems with wands and hoses and go in and spray the material they choose I use a body wax that is self healing and you drill holes for access then plug the hole with a small plastic plug. Wurth is my company but 3M also makes a good product and dispensers to go Takes less than a day to do a car properly that is already apart. Should be done by then a competent person who realizes the importance of what they are doing. Questions PM me. RacerJoe
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by MikeWilliams » Wed Dec 11, 2019 8:56 pm

Remember Lancia in the 1970s? High warranty claims due to rusting right through within the 12 month warranty period. Things have changed and that's one of the improvements of modern cars that we take for granted.

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by VFK44 » Wed Dec 11, 2019 11:50 pm

We recently had a Fiat for 15 years and when we sold it there was not a trace of rust on any of the bodywork. Mind you, it was built in Turkey by the improbably named Kok Holding company.
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by Pymmie » Wed Dec 18, 2019 8:27 pm

More updated photos from Jacek.

Probably one of the hardest jobs so far...

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by Grant » Wed Dec 18, 2019 10:41 pm

Brilliant isn't it.. shame its LHDImage
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by mikebyrne » Fri Dec 27, 2019 9:28 am

I read somewhere that it took two men 40 hours to weld up the CV8 chassis , but they had the advantage of having all the sheet metal sections etc. ready made to hand.
Making patterns, marking out the sheet metal, is what adds up the hours.
Some brilliant workmanship there.
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by Frankoid » Fri Dec 27, 2019 9:45 am

So he has used an old roof panel, answers that question. Perhaps the chassis number of the donor car will be reused in the new car. Fascinating stuff.
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by Pymmie » Fri Dec 27, 2019 10:26 am

Frankoid wrote:So he has used an old roof panel, answers that question. Perhaps the chassis number of the donor car will be reused in the new car. Fascinating stuff.


He is going to make a new roof panel as none are available.

If successful I’m sure there will be a market for them.

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Understeer - Hitting the fence with the front of the car
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Horsepower -How fast you hit the fence
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by Steve Payne » Fri Dec 27, 2019 4:46 pm

There are also a lot of cars that could do with tailgates, I wonder if he could also make these?

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by mikebyrne » Fri Dec 27, 2019 5:19 pm

Looks like this man has a Pullmax among his fine collection of workshop tools. David of Classic Metal Shaping, based near my place owns two of these machines and has several videos on Youtube, for example the link below shows one of the machines in action.
https://www.youtube.com/watch?v=EBdwCQ5l0eE
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by Grant » Fri Dec 27, 2019 5:50 pm

mikebyrne wrote:Looks like this man has a Pullmax among his fine collection of workshop tools. David of Classic Metal Shaping, based near my place owns two of these machines and has several videos on Youtube, for example the link below shows one of the machines in action.
https://www.youtube.com/watch?v=EBdwCQ5l0eE
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by Pymmie » Tue Dec 31, 2019 5:06 pm

Last few photos from Jacek for 2019.

Windscreen jig and A-pillars made.

2020 will be a big year for this car...

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Mk3 Int 128/4451 - SW Area Rep (Devon/Cornwall)

Understeer - Hitting the fence with the front of the car
Oversteer - Hitting the fence with the rear of the car
Horsepower -How fast you hit the fence
Torque - How far you take the fence with you
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by MikeWilliams » Tue Dec 31, 2019 9:18 pm

Whilst doing all that work can he make some changes to the cill design to reduce the rust problem there? That seems like the first place to go on most Interceptors.

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