May I introduce RollsRoyce, the new family 1982 RRC

dieseldog69 said:

@Gottschalk you should be watching this build mate, give you some inspiration for your RRC

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Well, at the moment it is mainly rust treatment and prevention, luckily she didn't have a lot of rust spots. But be safe than sorry, right?

Also, the carpets are cleaned by now (the original carpet floor mats at that!). The real building, fitting the by then modified roof rack, some drawers in the back for camping trips and so on will follow later this year (read: winter maybe). Other things to do: new exhaust, new brake pipes (the steel ones don't raise too much confidence in some spots), maybr new engine gaskets and a ne cam (not sure on that, the one fitted should still fine for a couple miles). But I'll keep this post up to date!

So, I guess today was the "low point" of the project, meaning the turning in which I stop removing stuff! Aside from two small bits to scratch off and remove, today 14:30 marked the moment where stuff gets added again!

The new front inner wings arrived are half way prepped for fitting, the three rust holes she had are plugged and half of the chassis got the first rust treatment. Also the rear wheel arches got the first prepping for the interior paint which will be done tomorrow. Same goes for the first rust treatment of the chassis.
Maybe I see the light at the end of the tunnel, or it is just the sun shining through a rust hole in the tunnel wall.... who knows...

Rust treatment done, only driver's floor panels and rear left floor panels to be painted. The wheel arcs and sides of the truck will be spayed later, much later...
The new upper tail gate frame was fixed today, tomorrow will see the front inner wings. After Easter the body panels and lower tailgate are due back from the paint shop.
Things to be done, still:
- back sheets of the door trims
- sound deadening
- carpets
- repair the cuby box
- improvise a new headlining
- new brake hoses ( I WANT Goodrich ones!!!)
- new shocks front and back (the back already has two good ones in the dual shock set-up)
- the draws for the camping trips
- modify the roof rack
- repair the snorkel
- general service ( filters, oil,...)

Well, I guess that's it!

Front inner wings are in (and the brakes totally dry now...) as are the floor panels.

Fitting the left one under the servo assy, where the servo is supposed to be , was a royal pain. And the right one deviates appr. 5 mm from the original one in certain spots. Fitting the body panels and everything else will get interesting, that's sure. Put holes are easily drilled!

Some bits on the work itself:

- all panel have been clued in with Sikaflex as well to keep water out and get additional strength
- Inner wings have been fixed with Sikaflex as well, especially in the places the original ones rotted through
- as the welding on the new inner wings around the wheel arcs wasn't as good as the old ones the seams got a treatment with Sikaflex as well
- wheel arcs covered with Raptor coating (long term experience outstanding)
- the inner wings got screwed to the horizontal edges of the bulk head from underneath with self-tapping screws, some new holes needed to be drilled. Otherwise it would have been impossible to access with the servo assy in place. We'll see what the TÜV says.
- old upper tailgate frame had to be cut to pieces to get the window out, as a result a screw had to be drilled out of the handle. The new one is to short now...
- The parts where the frame attaches to the hinges aren't held within the frame by anything else than the screws for the hinges. So either the tailgate goes back on horizontally or I need to clue in the reinforcements

So that's it for now, in update in two weeks or so. Then with the painted and refurbished body panels!

What it looks like at the moment!

It took a while but there is some progress. The body panels came back from the paint shop, the lower tailgate and the upper tailgate fitted now. In case it helps someone else fitting one the aluminium upper tailgate frames: The holes for the dampers are not threaded, so if you want to avoid cutting threads using pliers, cut them before the window goes in. Also the left rear wing has been fitted. The rear looks pretty much like car now. Well, at least from a certain angle...

Also all the parts in engine bay, left hand side, have been reattached to the inner wing.

So all in all, the car can be locked again. And it stays dry. Also, two pretty big orders for parts are in the making. Mostly I want to have stuff and less I need to have, but hey it's RRC!

Tricky things to do:

Fitting the front, radiator and stuff. I am SURE that the replacement inner wings have different dimensions than the original ones! Replacing the body mounts, removing the crap electric windows with more authentic manual ones, fix the wiring in the front (engine bay, head lamps, mystery switches, damaged cables,...), fitting new shocks (2 at the back to supplement the Sachs ones in a double set-up and the two front ones).

Less tricky: Goodridge flexi brake hoses, oil change, sound deadening, carpets, new seat belts, custom headlining, radio, modify the roof rack, drawers in the trunk, some painting, propshafts and u-joints.

Damn, I don't have enough spare time anymore!

Getting there, what paint you smothering it with?

The black? Brantho Korrux Nitrofest. That is some anti-rust primer / paint that can be painted directly on stuff like Owatrol Oil and painted over with anything else. Underneath is either Owatrol or some rust converter. Same on the inside, just that the surfaces that are not going to be covered by sound deadening and such will be spray painted with it. The rest, including the chassis, got a good touch with the brush.

It's progressing, slowly but I guess I'm getting there!

The rear is done except for the rear lights, electrics are saved for the end. The body is now fully repainted everywhere.

And since pictures are telling more than words, here you go!

Oh, and one last thing I discovered. The aerospace rubber and seal care from Liqui Molly is magic stuff! Saved me to replace the lower tailgate seals already!

It was a pretty productive week-end at 35 degrees and plain sun. But hey, it is done! Meaning, and here's the but, all parts a mounted, the seats are in, the lights are back on, brakes are vented, seatbelts replaced, back seats painted (colour turned out too orange, so that's to be done again later in sand)... So the car would be ready for TÜV in July, the beaty pegeant stuff like headlining and sound deadening have to wait.

Only thing NOT working: She refuses to start! Ignition control light is on, fuel pump is working, carbs are working. Electrical systems are all working as well. Still the engine doesn't turn. My assumption is contacts to the starter or alternator. I found one starter mass that was not properly connected, and where it is connected now (loads of protective paint) could be an issue to be tested out later.

So, any ideas on other root causes? Electrical systems aren't my strong suite...

Pictures to follow!

So, didn't find time to reconnect the start motor relay, well rather the second pair of hands I need didn't. So I took care of the paint today, some polish and it's going to look like new.

Some pictures of last weekend's and today's work:

Well, today started well enough. The new u joints were the plan for today. Were, because the first one went in like a charm. Then problems started. Turned out the destroyed u joint caused were in the shaft, now the bores for the u joint caps aren't round any more... It somehow never stops... But a new propshaft is easy enough to order and fit. The first part of which is done!

Tomorrow starter motor, some paint jobs, washer blades and door panels. Then the propshaft once it is delivered. Then to the paint shop for the roof, then the TÜV. And then the sound deadening and carpets. Ah, yeah, and the drawers, fridge and bed in the back. Is it just me or are things never ending?

So, besides killing the electrics I did something productive this weekend! Doors are repainted where needed and all missing bits and pieces added, door seals are back in, three still original and the brown / beige cloth on the last one need to be removed and put on the replacement. Also the hood got the first polish done.

Looks like your building to a good spec keep the pics coming

Thanks! Some motivation always helps!

Had a day off today. Exterior is what I consider done with the exception of the roof which has to be professionally repainted are clued to the body. All polished and waxed, not perfect with some spots of slightly darker shade of Sahara Dust and some black, tiny spots of unknown origin. Still most of the paint is now 36 years old so I think it's fine enough. Seat belts are now fully as are the interior side panels. TÜV is now scheduled for July 26th.

Jobs to do:
Rear propshaft (8 screws, what could possibly go wrong)
Bonnet release cable
Electrics (relais are ordered, left front indicator, interior lighting, reverse light)
Head Lining
Radio
Sound deadening and carpets

If everything goes well she's driving again this weekend!

The electrical issues are solved for the most partthe engine is turning again! And the PU-foam sheets for the new headlining are in since today. And the new propshaft is in as well. All in all thr last two days were pretty, well, nice!

Looks amazing! Health to enjoy, my friend! If you ever get to drive it to Ireland, I'd love to meet up!!!