View unanswered posts | View active topics It is currently Wed Dec 19, 2018 11:08 am



Reply to topic  [ 47 posts ]  Go to page Previous  1, 2, 3, 4, 5  Next
Mike's Elva Courier MkIV Build Thread! 
Author Message

Joined: Sat Feb 07, 2015 4:25 pm
Posts: 18
Location: Rochester Kent
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
WOW ! Excellent stuff..............and I thought I had a project on my hands !
Go for it ..... and all best wishes and good luck Mike 8-)
Regards
John


Fri Mar 06, 2015 4:14 pm
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
johnwhite wrote:
WOW ! Excellent stuff..............and I thought I had a project on my hands !
Go for it ..... and all best wishes and good luck Mike 8-)
Regards
John

Thanks, John! I'm really hoping to get everything finished for the Elva reunion in September, but I've gotta find those few engine parts first!


Sun Mar 08, 2015 1:45 am
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
Not an update per se, but some exciting finds! :D

First, I found a good used Titan 5-port dry sump oil pump:
Image
Image

I also found an awesome std/std forged 6-bolt crankshaft, good for 8,000rpm (more than I'll use, of course)!
Image
Image

And I took some time after work to clear a bench and get ready to assemble my gearbox with Dad! I have a few parts there now, with a bunch more to move:
Image


Sat Mar 21, 2015 2:52 am
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
Time for another update! I was able to remove the rear axle housing from the car and bring it back to the shop:
Image
Image

I wiped it off and removed the brake drums (with a screwdriver and a hammer) to see what things looked like:
Image
Image
Image
Image

Both drums were pretty rusty and one of the slave cylinders was leaking, but the shoes are probably passable. I decided to sandblast the drums to remove the rust and check for cracks:
Image
Image

Good thing I did:
Image
Image
Luckily we have a spare drum around here somewhere.

With the drums off, I slid the axles out some and removed the ring and pinion:
Image
Image

10-year-old gear oil is pretty interesting stuff!
Turns out I have a 4.22 welded rear! Guess I'd better try to find some footage of Mark Donohue!
Image
Image

I also got a box filled with the Courier's old front suspension pieces!
Image
A whole front end assembly plus half the steering column and a spare lower control arm. I immediately removed all the bushings and got ready for the sand blaster:
Image
Looking better!
Image
Finally, I got a few coats of paint on everything and it's ready for new bushings and assembly!
Image

I've got both front uprights (which will have to be crack tested) and the one surviving front coilover to use as a reference!
Image

I'm getting excited!


Sun May 03, 2015 3:30 am
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
Another small update!
I pulled the axle housing out again and took a quick look at the floating hubs:
Image
Everything came apart pretty easily and I made sure to label the brake backing plates very carefully:
Image
I packed the hubs, set screws, and other bits in two bags for later:
Image
Next, I took at look at where the bottom halves of the radius rod brackets had been cut off. They looked pretty gnarly:
Image
Image
After a bit of grinding:
Image
Image

And one more kicker: Apparently the brake drum wasn't the only cracked piece:
Image

Womp womp.


Tue May 05, 2015 12:04 am
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
I got back from Summit Point at midnight, but I still had plenty of energy to do fiberglass work today! I made what I think is quite a bit of progress. I'll post everything as a "before" and "after."

First, I did all of today's work with the car on a rotisserie at this angle:

Image
It made some parts a bit easier and some MUCH harder.

I started with a seam on the passenger pedal box:
Image
Image
Image

I patched up the inside of the panel I'd previously attached:
Image
Image

I filled a couple cracks/cuts around the hood opening:
Image
Image

Image
Image
Image

I also cut a couple patches for holes in the firewall and taped them into place:
Image
Image
Image
Image

I filled a seam between the left inner fender and the nose, as well as a large hole under the nose:
Image
Image

I cleaned up along the firewall and sealed it:
Image
Image

Finally, I fixed two large cracks and a hole in the rear of the car:
Image
Image
Image
Image
Image
Image
Image
Image

Finally, the hood finally fits properly!
Image

We did have to...modify it a little to get it to fit though:
Image

That's all for now, but I felt pretty accomplished!


Mon May 18, 2015 11:40 pm
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
It's been an unbelievably busy season thus far and I've only just gotten some time to work on the Courier again. There are some things I didn't get pictures of, but this will get the idea across for now!

I've been heading to the shop where the car is located after work, usually after the owner is done for the day. The last couple times I went, nobody was there and I couldn't figure out how to get the compressor turned on. That meant instead of grinding the areas I had to fiberglass, I had to file them by hand. Took a while longer but worked alright!

The biggest news first: We have one of the doors fitted! We had to remove a bit in front of it to get the hinge to work, but we'll add it back in once it's settled.
Image

On the other side of the car, I did a bit of smoothing out around the front and rear of the left-hand door.
Image
Image

I reattached the two halves of the area underneath the car's "mouth."
Image

There was a hole after reattaching the upper part of the mouth, but I forgot an "after" picture of that. (It's filled now)
Image

I cleaned up the area between the passenger footwell and the inner fender:
Image
As well as attaching the footwell to the chassis rail.
Image

A super-nifty bar has been added under the front cowl so I glassed one of the feet to the chassis (it's been welded already, just so everyone knows):
Image

I also started to attach the center of the bar to the underside of the cowl:
Image

I sealed up the gap between the rear shelf and the underside of the rear cowl. This part was pretty tough as the glass mat had to wrap from a vertical surface to the underside. I started with a single piece but discovered it was too heavy so I used three smaller pieces with more success.
Image
Image

I cleaned up the rear vertical members of the chassis so I can reattach them to the body:
Image
Image

Then I stuck them together!
Image
Image


On a different note, the transmission tunnel is almost completely done and will ultimately be attached with screws for easy removal!
Image


Mon Jul 20, 2015 12:41 am
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
HUGE update, guys! I've been working full days at the shop, then heading to the Courier and working there! Lots of pictures, so hopefully you aren't reading this on a phone with a limited data plan! :D

First off, my sister did her first fiberglass work a couple weeks ago! Her first experience was with the hood. We had to spread it slightly on one side to get it to match the fender:
Image
After a quick tutorial from yours truly, she got to work!
Image
Image
Image
Great results!
Image
I also showed her how to use leftover resin to fill in rough spots, and she smoothed out this bumperette:
Image

Before we left, I prepped a number of areas for future work:
Image
Image
Image

I also got a nice preview of the second inner fender!
Image

A lot of work got done on the rear firewall and interior!
Image
Image
Image

The inner fender is glassed in!
Image


We also made some super-nifty pieces to locate and secure the transmission tunnel!
Front:
Image
Rear:
Image
Along with some screws, these will allow us to remove the tunnel quickly and easily to access the transmission!

My next visit, I discovered my car at this orientation:
Image

Time to look at the underside! :D
Glassed the back of the rear firewall, under one of the front fenders, and filled some small gaps with the extra:
Image
Image
Image
Image

These final pictures are from today. First of all, it appears we won't be keeping the front bumperette "whiskers:"
Image
I've seen a car without them, and I have to admit it looks quite nice. Hopefully mine will come out as cleanly!

First off, the new gallon of resin was slightly....dried out about four inches in. I had to drill my way in:
Image
That was annoying.

Once I had the resin, I got a number of areas stuck together! Patched the underside of the fenders, the old rollbar holes in the rear, areas around the floor, gaps between the inner and outer fenders, some small gaps in between other panels, and a couple small cracks.
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image


The car is almost ready to come home and then I can make it into a roller!


Sat Aug 08, 2015 3:39 am
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
Another update, and another evening spent covered in dust and fibers!

I took pictures of most of my target areas before I worked today, so there's a good "before and after" this time.
Areas I worked on include...
The gaping hole that was once the right-hand whisker:
Image
Image
Image

A small patch on the right inner fender:
Image
Image

Holes in the rear firewall and tail area from the old rollbar:
Image
Image
Image
Image

The left-hand inner rocker:
Image
Image
Image
Image

I also covered a small gap between the rear firewall and the rear of the chassis to prevent rubber and rocks and things from getting trapped in there:
Image

Oh, and we have a roughed-out rollbar sitting in the car! Woo! It'll need a couple more bars obviously but I like it so far!
Image


Mon Aug 10, 2015 2:19 am
Profile

Joined: Tue Jan 28, 2014 7:09 am
Posts: 68
Location: Hopewell Junction, NY
Reply with quote
Post Re: Mike's Elva Courier MkIV Build Thread!
So I was finally able to pick up the engine block and transmission case yesterday to take home and start working on!
Image

I separated the case and started preparing to clean the pieces. First, I took a look at the center section:
Image
It had a fair amount of rust, so I decided to glass bead it. I think it came out well!
Image
Image
Image

I'll spend a bit more time making 100% sure all the grit is out of the drillings, but I'm confident it'll get nice and clean.

Today, I decided to work on the bellhousing. It's cast iron, like the rest of the drivetrain is (unfortunately...). Here's my starting point:
Image
Image
Image
First order of business was removing the throw-out bearing arm pivot!
Next was removing the mount for the throw-out bearing arm and a section of the starter shield. Here's my dad's bellhousing as an example of my goal:
Image

Using a combination of hacksaw and cutting wheel, I got the mount first...
Image
...and the shield second.
Image
A bit of work with the angle grinder and I'll be good to go! Not bad for a rough cut!
Image

And by the way, it looks like I saved a pound of weight with my cutting!
Image

Next is painting the cleaned pieces, cleaning the second brake drum, organizing the parts for the gearbox and rear axle, and--dare I say it--some assembly!


Thu Aug 13, 2015 1:52 am
Profile
Display posts from previous:  Sort by  
Reply to topic   [ 47 posts ]  Go to page Previous  1, 2, 3, 4, 5  Next

Who is online

Users browsing this forum: No registered users and 1 guest


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  
cron

Protected by Anti-Spam ACP Powered by phpBB © 2000, 2002, 2005, 2007 phpBB Group.
Designed by STSoftware.