1990/G c900 Carlsson restoration.
part 1 - engine, gearbox and engine bay
Shedule of works:
Customer car that is in reasonable condition for its age and mileage, but is in need of a full restoration to bring back to its former glory. The car is in regular use, and the customer has requested the rebuild in stages. Part 1 is to overhaul the engine and gearbox, whilst the engine is out of the car the engine bay will be grit blasted to reveal any corrosion, repairs where necessary and repaint. The gearbox will be reconditioned and the engine overhauled including headgasket, timing chain, oil pump etc. The air conditioning system is to be removed and refurbished cam cover, inlet manifold and sundry pipes, brackets etc will complete this stage of the restoration.
At a later date stages 2, 3 and 4 will cover the exterior repaint, suspension/braking system and interior.
Customer car that is in reasonable condition for its age and mileage, but is in need of a full restoration to bring back to its former glory. The car is in regular use, and the customer has requested the rebuild in stages. Part 1 is to overhaul the engine and gearbox, whilst the engine is out of the car the engine bay will be grit blasted to reveal any corrosion, repairs where necessary and repaint. The gearbox will be reconditioned and the engine overhauled including headgasket, timing chain, oil pump etc. The air conditioning system is to be removed and refurbished cam cover, inlet manifold and sundry pipes, brackets etc will complete this stage of the restoration.
At a later date stages 2, 3 and 4 will cover the exterior repaint, suspension/braking system and interior.
Initial condition:
The engine and gearbox, whilst having received standard servicing, have not had any major work carried out and are showing signs of age and mileage. The engine bay looks to be in need of some welding repairs, especially around the battery tray area. Signs of past repair work can be seen on both inner wings infront of the wheel arches.
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The engine and gearbox, whilst having received standard servicing, have not had any major work carried out and are showing signs of age and mileage. The engine bay looks to be in need of some welding repairs, especially around the battery tray area. Signs of past repair work can be seen on both inner wings infront of the wheel arches.
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Pictures of the car before work commences: (click pictures to enlarge)
w/c 30/11/09 removal of engine / gearbox
As can be seen from the above pictures (click them to enlarge), the engine is long overdue some care and attention. The gearbox oil shows signs of metal silvering, a sign that all is not well inside the gearbox. The engine oil is dirty but not contaminated. We will have to wait to examine the engine internals, but the engine ancileries and other components are in a bit of a state. As shown above, the front enginne mount is in two pieces - totally collapsed. the other 2 engine mounts are showing signs of severe wear. The clutch master cylinder is very rusty and worn, the clutch feed pipe is nearly holed due to corrosion. The o/s driveshaft tripod bearings are very worn, as is the gearbox driver. The wiring loom needs a lot of attention, with some very corroded connectors and wiring. The exhaust down pipe is holed where the gearbox exhaust mounting fixes to it.
Closer examination of the engine bay after engine removed:
From the following photos it can be seen that our initial assesment was just about right - there have been some past (poor) repairs to the inner wings and signs of some past plate welding that has also been poorly done. the area under the battery tray is very corroded. Once the engine bay has been grit blasted next week we will be able to assess the rectification work more thoroughly.
w/c 07/12/09 Grit blasting the engine bay
Following the grit blasting, we were able to see the extent of the damage. LOTS OF WELDING will be required here! You can see the bodge repairs to the front inner wheel arches by the quantity of filler!
The areas of corrosion will all be cut out, and then fresh metal welded in. Not shown is the front slam panel, that also requires some repair work around the towing eyes and under radiator support rail. However the GOOD NEWS is the main strutural chassis rails, and the drive shaft tunnels, are in good condition!
The areas of corrosion will all be cut out, and then fresh metal welded in. Not shown is the front slam panel, that also requires some repair work around the towing eyes and under radiator support rail. However the GOOD NEWS is the main strutural chassis rails, and the drive shaft tunnels, are in good condition!
w/c 14/12/2009
Whilst the car is away at the bodyshop, a more detailed examination of the engine was carried out. More pictures will be posted soon, but here you can see that it looks like the car has been run without antifreeze. Antifreeze acts as a corrosion inhibitor, and you can see the extent of the corrosion inside the waterpipes, waterpump housing etc.
w/c 21/12/2009 car back from the bodyshop
As can be seen from the following pictures, all the engine bay welding work and repainting has now been completed:
Slam panel after welding and powder coating:
