Project "Plonker"

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Re: Project "Plonker"

Postby mec » Fri Apr 24, 2020 3:04 pm

Hi All

Hope you are all well and finding lots of car related stuff to do !
Thought i would give you some more reading on Project Plonker, il carry on from the last post, the front end was completely attached, the passenger corner was the last bit, so this is now all done...

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there was also some further renforcement to the under bonnet area on the drivers side bonnet area...

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so next i wasn't really very happy with one of the 1st repairs I did on the passenger side lower wing area, as I have a section of wing off the white front end, i decided to redo this repair...

i started with this...

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and ended up with this ...

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this took an age as i had to do the fibreglass in sections to get it to fit correctly, im much happier with the repair now

Next was the drivers side rear arch, i had one section of this to fit but the lower corner was totally missing, now i was going to cut the bits i needed off the saloon rear but i have potentially sold it as it is so didnt want to cut any more chunks out of it so i came up with this ...

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This centre repair i actually used a lower corner bit of the arch I had, its not quite the right shape but has given a good basis to fill and shape on

I have also repaired both door lower hinge areas...

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next i wasn't happy with the strength of the floor repairs where the body bolts on, although they are very strong i wanted to go belt and braces so i buzzed back the repair areas on the inside and renforced them so the thickness is now doubled and fibreglassed from both sides...

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whilst im inside the van i noticed one of the roof struts was cracked in 2 places, so these are now repaired...

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also whilst inside the van a small repair was needed in the passenger side footwell..

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there are also 2 repairs to the door apertures, 1 either side where the shell has been picked up carelessly in the past

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Back on the front end, there are a couple of repairs around the no plate area and also I have finished the bumper corner repair, and i added a reinforcing strip right across the underside of the bonnet from wing to wing, then before i fitted the air scoop section back on i painted the bonnet area with stone chip as this would not be accessible once the scoop is on...

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then fitted the air scoop...

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Finally, I have started sanding ! ...

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Oh and incase you were worried, i saved the dog on the front of the van...

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He will be moved elsewhere as a van mascot ;)

And just for you Julian, proof that the rear floor is strong ...

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:dance: :dance: :dance:

Next up is the other piece of the air scoop to go in and finishing the top of the rear bumper, i can then start the filler work and painting the rest of the underside, i will keep you posted :thumbsup:

Stay safe everyone :mrgreen: :mrgreen:
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 Dan 6511 » Fri Apr 24, 2020 3:20 pm

Top work as ever, you wouldn't think it was the same van :thumbsup:
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Re: Project "Plonker"

Postby mec » Sat Apr 25, 2020 9:19 pm

Thanks Dan its certainly been a journey !
NTH347X... now DMC 81X
Mike C aka MEC
vin - #4395



2009 DMC Europe open house Roadtrip member
Official 2010 Silvercoast "Chaved Banana"
Unofficial 2011 Eurofest Autotest WINNER ! 128.7 secs
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Re: Project "Plonker"

Postby bandit » Sun Apr 26, 2020 7:39 am

Nice work as ever Mec, thumbs up on the floor & the rest of it for that matter. You must be high as kite with that glass fire in ya garage ;) :)
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Re: Project "Plonker"

Postby mec » Mon Apr 27, 2020 12:45 am

Thanks me Julie, yea it does get a bit fumy in there at times, not to mention the poxy dust !! Still it will be worth it in the end :thumbsup: :thumbsup: :mrgreen:
NTH347X... now DMC 81X
Mike C aka MEC
vin - #4395



2009 DMC Europe open house Roadtrip member
Official 2010 Silvercoast "Chaved Banana"
Unofficial 2011 Eurofest Autotest WINNER ! 128.7 secs
2013 Silvercoast DMC Roadtrip Representitive
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Re: Project "Plonker"

Postby cis6409 » Mon Apr 27, 2020 7:14 pm

Wow that's coming on leaps and bounds mec, some job!
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Re: Project "Plonker"

Postby Admin-bloke » Mon Apr 27, 2020 8:11 pm

Great lockdown pics Mike, cheered me right up
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Re: Project "Plonker"

Postby mec » Tue Apr 28, 2020 10:26 am

Thanks guys for the continued nice comments, I hope you guys don't mind me putting it up, I know its not D related, I'm glad it cheered you up Mr T :thumbsup: :thumbsup: :dmcdoors: :mrgreen:
NTH347X... now DMC 81X
Mike C aka MEC
vin - #4395



2009 DMC Europe open house Roadtrip member
Official 2010 Silvercoast "Chaved Banana"
Unofficial 2011 Eurofest Autotest WINNER ! 128.7 secs
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Re: Project "Plonker"

Postby mec » Sat May 09, 2020 11:33 pm

Hi All,
Hope you are continuing to stay safe, here's a bit of evening reading for you with an update on Project Plonker...

At the end of the last post I had fitted the front half of the air scoop, however before i could fit the back half there were a couple of jobs i had to do first, the first thing was the A pillar reinforcements, on the shell these are the only metal items and as you would expect as with everything else on the van that was metal, they were rotten as a pear...

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you can see in this picture from the outline of the fibreglass that there is about 2 inches missing off the end, the other end which goes down to the bottom of the A pillar and under the front wing has also dissolved...

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So i proceeded to cut both sides out and made replacement ones out of solid stainless steel rod rather than the original hollow tube...

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new ones made...

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these were then fibreglassed in ...

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Now these areas are complete i had to repair the rear of the dash in a couple of places..

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Then the rear of the dash and foot wells could be cleaned and stonechiped...

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Now this was done i could start fixing the rear half of the scoop in...

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Once this was all fibreglassed in and strong,it also received a coat of stone chip along with the rest of the inner wings...

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You can see in the last picture i took the time to mask the original number code on the drivers side inner wing, this is suppose to be the date the shell was made, but this is not the case with mine as the regal went out of production in 1973 so could not have been 1980 as the numbers suggest.

Now this was complete there were only one more big-ish bit of fibreglass to finish which was the rear bumper area, some CAD (cardboard aided design) was needed for this...

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After a few more small repairs the fibreglass stage is Finally COMPLETE !! :dance:

BUT I cant get to excited as now I'm onto the filler stage !
To start with i wanted a fibreglass filler to use for all the big repair areas and where the panels had been joined so i used this ...

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This fibreglass filler is also renforced with Kevlar so should be just what I need, I have done various areas so far all round the van, here are some of them...

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You get the idea on this, this side panel needed 2 layers of the fibreglass filler before i then moved on to a more conventional finishing body filler made by the same company Evercoat, this filler is called Rage Gold and is a very nice bit of stuff, here you can see the side panel now it has a layer of this added...

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Now although this still needs finishing as there are a couple of divits that need going over its certainly better than the bullet holes that were in it :D

I've also started repairs to the roof and passenger front wing with the finer filler now too, and wherever there have been cracks in the Gel coat i have just a Dremel and gently grooved these down to the fibreglass so the filler has something good to key to, looks like i have tree bark effect body panels...

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Again the front wing requires more work but its a definite improvement, that's it for now guys, i think its safe to say ive got a lot more sanding to do yet :doh:

stay safe :thumbsup: :thumbsup: :thumbsup: :mrgreen:
NTH347X... now DMC 81X
Mike C aka MEC
vin - #4395



2009 DMC Europe open house Roadtrip member
Official 2010 Silvercoast "Chaved Banana"
Unofficial 2011 Eurofest Autotest WINNER ! 128.7 secs
2013 Silvercoast DMC Roadtrip Representitive
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Re: Project "Plonker"

Postby Admin-bloke » Sat May 09, 2020 11:43 pm

:thumbsup: :thumbsup: :thumbsup:
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