Danish 294 Posted October 28, 2018 Some good ideas and feedback there, thanks. Mark - I think the big K logo will only be possible if I mask and paint it red. Designing with CAD then having it machine-cut in vinyl is my preferred way of working. Tony - yes, probably something that could be done with the sides. Rich - yes, clearance might be a problem, but I can always duct the air away elsewhere if I need to. Also, I will probably get a custom rad made, so it could be virtually any shape. Quote Share this post Link to post Share on other sites
Danish 294 Posted October 30, 2018 (edited) The first job today was to prepare for a visit from Dave.com tomorrow. I'm not sure what engine this is. Maybe those 8 ports mean it's pre-crossflow? Then making a thing - hacksawing a length of 38mm aluminium: Centre tool, using the 13-25mm chuck for the first time: Turning down: Fitted to the DOHC pulley: So I can use the 'dead centre' tool on the mill to accurately locate the centre of the pulley: Edited October 30, 2018 by Danish 1 Quote Share this post Link to post Share on other sites
Danish 294 Posted November 2, 2018 Since adding the roof-rack to PAL, there wasn't as much need for the boot-lid-mounted spare wheel. I never finished the gas strut modification, so the boot lid is hard to lift, plus it obscures the rear view which is already limited by the roll cage. So last year I started work to swap to a different boot lid, but that was delayed and as we all know primer isn't water proof and it had developed some rust. Unfortunately I used seam sealer and that seems to have trapped in moisture as well, so the first job was removing that: DA to take back the lower edge of the lid to bare metal: Kurust for the less bad areas. The worst bit will get new metal welded in. Quote Share this post Link to post Share on other sites
Danish 294 Posted November 2, 2018 Our afternoon session started with filler on the bottom edge of the boot lid: The with a bit of high-build primer it's ready to hand over to the paint shop on Monday. I've done my bit painting the car, in future it will be done with 2-pack. SWMBO, the DA and the spare bonnet, dressing around 50 welds that are holding it together for dipping: The paint is hard-as-nails so presumably 2-pack. It was thick and I suspected there was more than one colour - but sanding showed two sets of colour, both the same shade: About three-quarters of the way there: Hopefully this paint can be used by the paint shop, though I'm not sure whether it's 2-pack or not. We'll be going with the same design as the previous bonnet (as per comments further up in this topic) Quote Share this post Link to post Share on other sites
chris mk3 325 Posted November 2, 2018 Yes to two pack, tryed n tested and still the best paint Quote Share this post Link to post Share on other sites
Danish 294 Posted November 2, 2018 (edited) Yes to two pack, tryed n tested and still the best paint Yup. The red paint I used is good - that's Halford's acrylic aerosols. But the yellow (internet cellulose aerosol) didn't ever fully harden and it's shrunk back from the decals in places. So fitting the new bonnet and boot is a chance to replace a fair amount of panels in yellow aerosol. Edited November 2, 2018 by Danish Quote Share this post Link to post Share on other sites
Danish 294 Posted November 3, 2018 (edited) How a little job becomes a big job. I wanted to charge the Cortina's battery, but didn't want to risk the boot lid dropping on my head, so we thought to remove the spare wheel. Then found the paint was so damaged underneath we may as well strip and remove it and send it with the bonnet for dipping. The paint is right through to primer where the spare wheel cover touched it. There's not much to do except strip it back, and the soft paint would be a nightmare to sand off, so dipping seems the way forward: Fog lamp, ham aerial and spare wheel carrier stripped off: This original boot lid didn't have much in the way of bracing for the spare wheel. The paint was cracked across that side of the boot lid showing the metal has been flexing: Boot lid removed. This should make it easier to fit the rear window blind: I imagine the dipping process would take off the vinyl decals without even noticing, but I removed them just in case. Stacked with the bonnet ready to go: Edited November 3, 2018 by Danish 1 Quote Share this post Link to post Share on other sites
Pete-H 69 Posted November 3, 2018 At least you have found it now rather than when the panel had fractured and started flopping around. Quote Share this post Link to post Share on other sites
Danish 294 Posted November 3, 2018 At least you have found it now rather than when the panel had fractured and started flopping around. Indeed. Once it's been dipped I'll have the holes for the spare wheel welded up, and put a few welds inside to strengthen things up. After that for now I'll probably paint it with Bondaprimer and a light top coat of something or other to keep it from rusting until we're ready to do the next colour scheme, probably in 2021/22. 1 Quote Share this post Link to post Share on other sites
Danish 294 Posted November 9, 2018 (edited) Nice work from the admin team. Now I can upload photos direct from my phone! On Tuesday I delivered the boot lid and bonnet for dipping. Edited November 9, 2018 by Danish 1 Quote Share this post Link to post Share on other sites
Danish 294 Posted November 15, 2018 It's been 7 years, there's 271 pages with 5,732 photos! I think it's the second longest ever topic, behind Swampy. Quite staggering really. But for a number of reasons it's time to draw this thread to a close. I've set up a Facebook page for the continuation of the project PAL - the endurance rally Mk3 Cortina where I'll be doing some more in-depth posts and videos. Quote Share this post Link to post Share on other sites
FKLGLS 44 Posted November 16, 2018 It’s been a brilliant build and a really entertaining thread has this. A shame that it’s only going to continue on Facebook as there are a few on here who aren’t on there, but your reasons are your reasons and should be respected. I personally would like to see updates on PAL on here as I have felt for some time now that this forum has sadly began to tail off and threads as good as this are the lifeblood of successful forums. However, I have found this build fascinating and will continue to follow it over on the other side and hope that you will still be a presence on Bsc as your talent and commitment is reflected in the number of views. Quote Share this post Link to post Share on other sites
sheffieldcortinacentre 764 Posted November 16, 2018 Me to it'll be a shame that it'll only be on faceache. Quote Share this post Link to post Share on other sites
swcortina 43 Posted November 16, 2018 Agree with above posts, these updates will be a great loss to bsc, it's been great following the thread, the pics and details have been excellent and very informative, I do use faseache but I'm not a lover of it and prefer the forum, I will continue to follow on the dark side, looking forward to the future pics and updates Jayne Quote Share this post Link to post Share on other sites
Danish 294 Posted November 17, 2018 On 11/16/2018 at 2:21 AM, FKLGLS said: hope that you will still be a presence on Bsc as your talent and commitment is reflected in the number of views. Oh no, you don't get rid of me that easily! 🙂 1 Quote Share this post Link to post Share on other sites
