Project "Plonker"

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Re: Project "Plonker"

Postby mec » Fri Mar 06, 2020 4:30 am

Thanks mate that was what i was going for, the explodaview type pic,

I know maybe the repairs don't look that neat from the front atm, but I'm getting all the strength back in the body 1st so i can work on the finishing after without it flexing, well thats the plan :? ;)
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Re: Project "Plonker"

Postby mec » Sat Apr 04, 2020 7:30 pm

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 .....
NTH347X... now DMC 81X
Mike C aka MEC
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Re: Project "Plonker"

Postby mec » Sat Apr 04, 2020 8:27 pm

So carrying on from the last post, after the sill repair i did another front drivers side panel repair and also a battery and foot well repair...

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So then comes the main event... THE FRONT END :shock:

Initially i was going to put in as little as possible to maintain the front end strength, but as a lot of the damage was so close together i later decided to put the front end on as one, this would make for a neater job and less joins, first though the new front end I traded mine for needed a repair, heres the new front...

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you can see the damage on the corner,

this was repaired 1st to make sure it was strong and the right shape...

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Also before fitting the front end i had to repair the drivers side front corner of the van so its also strong and the right shape...

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this looks a little rough atm but is very strong... so the main front ...

here are the planned cut lines ...

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So a BIG deep breath and..

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1ST test fit ...

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then cut to fit ...

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So there you have it, im really pleased with the front end, there is still some more to do but im over the hump of the fibre glass work now :dance: :dance:

Stay well everyone !!
NTH347X... now DMC 81X
Mike C aka MEC
vin - #4395



2009 DMC Europe open house Roadtrip member
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Re: Project "Plonker"

Postby DMC1983 » Sat Apr 04, 2020 11:00 pm

Well someones been busy. Looking good and coming along nicely
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Re: Project "Plonker"

Postby mec » Sat Apr 04, 2020 11:41 pm

Thanks mate, yea its definitely accelerated the project being off, glad to see you doing some on yours too !
NTH347X... now DMC 81X
Mike C aka MEC
vin - #4395



2009 DMC Europe open house Roadtrip member
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Re: Project "Plonker"

Postby Admin-bloke » Sun Apr 05, 2020 9:30 am

Great pics Mike, it's made my day seeing project pics
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Re: Project "Plonker"

Postby mec » Sun Apr 05, 2020 11:25 am

Thanks Mr T, hope you are getting a bit of garage time around your busy work schedule :kiss:
NTH347X... now DMC 81X
Mike C aka MEC
vin - #4395



2009 DMC Europe open house Roadtrip member
Official 2010 Silvercoast "Chaved Banana"
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Re: Project "Plonker"

Postby Admin-bloke » Sun Apr 05, 2020 2:14 pm

mec wrote:Thanks Mr T, hope you are getting a bit of garage time around your busy work schedule :kiss:


I've done more in the last 3 hours tidying the garage up than I have in the last year. I can almost get to the D now...!
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Re: Project "Plonker"

Postby bandit » Sun Apr 05, 2020 4:38 pm

Wow mec, top work young man. I liked the bit where you said you sat on the floor & it held your weight. I just had a vision of you going through with your head & massooove shoulders sticking out the top. Now that would have been the selfie of the year ;)
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Re: Project "Plonker"

Postby mec » Sun Apr 05, 2020 8:40 pm

Brilliant work Mr T !!

Julian you really made me laugh when i read that ! :lol: :lol:
Yea that would have made a great selfie but im glad it didnt happen lol :dance: :dance:
NTH347X... now DMC 81X
Mike C aka MEC
vin - #4395



2009 DMC Europe open house Roadtrip member
Official 2010 Silvercoast "Chaved Banana"
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