Hi all, hope everyone is well and safe in this crazy situation we find ourselves in, as you would imagine I have taken full advantage of the situation and spent quite a bit of time in the garage working on Project Plonker !
So il carry on where the last post left off...
Shortly after we got back from our Norfolk meet, i decided to do something with the saloon, I had a deal going with a guy local to me in Chelmsford who deals in Regal parts, he wanted a regal front end cut above the windscreen to turn into a photo booth for the Only fools and horses shows he does,
(he was trying to buy the saloon off the guy i got it from but i beat him to it) so i did a deal with him for my front end cut above the screen for another front end cut below the screen and some parts my way ...
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I must add i DIDNT want to do this !! but needs must
Before the Front end went, i had to cut off the inner air vent section which i need for the van
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I then cut off the rear bumper section off the saloon shell which i need for the van, this is pretty much identical barring the number plate light mount in the centre and also the saloon rear bumper is not as deep, but the way i cut it off, i included part of the inner bumper so this made it deep enough to use on the van..
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Before i could fit the rear bumper i had to repair another area of the rear floor area, this is the area in the following pic under the furthest metal brace in...
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from underneath ...
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I also put extra renforcement on the lip of the floor...
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I then repaired the passenger side lower side panel...
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I then jumped to the drivers front floor, this needed a repair which i wanted to get done so i could get the shell of the 2 tressels it was perched on and onto a custom made frame on wheels so it can be moved around, heres the floor...
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Heres the frame ...
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So then back to the rear bumper, now the shell is on the frame its much easier to manouver to get to the different areas, 1st off, i glued the rear bumper onto the floor lip...
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this was clamped between a piece of wood and angle iron until it set, then i started the fiberglass from underneath, the saloon bumper inner was square on the corners so i had to shape this is situ...
from this..
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to this...
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then it was all fibreglassed...
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The corners on this were particularly hard to get level but its not to bad...
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The rear bumper and floor area are not very very strong and just to make sure i actually sat on it and it took my 17st no problem, so when its on the chassis with the support frame underneath its not going anywhere.
I then moved onto a sill repair on the drivers side ...
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I will carry on in the next post as i have run out of pictures on this one... to be continued .....