Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!

[Grizz1963]

Went out by 10.00 this morning.

Cleared up a load of stuff around the workshop, packed materials away wtc.

Then pulled the original fuel tank down to take a look.



Opened up the tank.



Loads of crud inside.



While I was fighting the tank, Nick started to lay out more of the wiring loom and attaching it to the chassis and gearbox/motor.

I removed the tank and then banged it down on the floor in the hope to loosen up some of the crud.

Also had the cement mixer out, planning a load of nuts and bolts and self tapping screws to clean up the inside.

Unfortunately it was not to be.

Rusted out tank.




So now the next trick will be to to get a copy of this tank made up in either steel or ally plate, including the fuel pump etc.

Need to find a sheet metal builder who can copy this and make a tank.

[Grizz1963]

So after the loom and tank work, we carried on with various tasks, most ably led by @Nickwheeler who is a bit like a blood hound, once he cranks his head over and forward, only coffee and cookies or raisin bread slows him down.

The gearbox mount, though probably perfectly adequate, has been bugging him from day one.

So as I had removed the body to get to other bits, he removed it for some strengthening.



Some three handed welding, large ball pein hammer action later, it started to take shape, after the reshaped plate was made up.



Bolted back in place, Nick was a happy bunny.




At this point the body had to go back on again for the next job.



More about it later.

Work now.


PS. An MX5 tank for £40.00 off EBay looks like this,

Ugly.

Really ugly.

[Grizz1963]

Reflecting on the rusted out tank and the options open to me……

I contacted Darren at Unit Engineering in Queenborough on the Isle of Sheppey to discuss options.

So……………

Loaded.



Uploaded.



To be delivered to Darren when I get time, along with the MX5 fuel pump and return valve.

Then hopefully collect a rebuilt tank after X-period of time to fit to the chassis, in exchange for some cash.

I also popped out to fetch some Nyloc nuts and bolts for the rear shock absorbers, as well as the mounting bolts for the screen.



Baby steps every day.

Onwards in the words of @pauly

[Grizz1963]

Bonus ball.



.

[Grizz1963]

Went over to The Isle of Sheppey after work today.

I had decided to ask my friend Darren at Unit Engineering to make and adapt the new fuel tank to MX5 hardware.

Price to be confirmed on completion.



A typical old skool Rodder, he runs a few cars, well known down this way.

One of my all time favourites since childhood.

Firenza.





Then this 1000bhp when on Nitrous Chrysler Valiant.



And his Ford Pop.



And his current sideline build, a V8 chopped Beetle.



Funny how great minds think alike.

I really wanted to add a grenade shifter knob to the Rezin Rockit as well.

So I think we are going in the right direction.

One of the things I want on the front screen is a visor.

So Darren let me use his machines and tools to cut and fold a basic visor, which needs finishing and mounting.

Rather large cutter……..





Measure, fold, measure, fold, measure and fold…….

And done.



For now, but it needs some trimming and the angle of the visor cap to be changed.

As well as a bunch of holes and dimple dies to be added.

Should work OK.



Once done, a coffee and cake, and I was on my way, knowing the traffic had died down.


Fooled………

120 minute delay after a motor vehicle accident.

Road closed.

Burger !



Eventually back home I unpacked and had to go look to see how the initial mock up looks.



Angle needs to be changed with the peak dropping quite a bit lower, and also some large dimple die holes punched in the whole length.




Ready for bed, it was a long day.

Later.

[Grizz1963]

Got asked for more info on RetroRides

[quote author="@31coupe" source="/post/2718928/thread" timestamp="1644483973"]Ooooo that V8 Beetle build is epic!!! Any idea what motor he is putting in it? [/quote]


Rover.

And a big round blowy thing.



Turbo.

[Grizz1963]

Ordered a new spre bottle of Argon/CO2 this week.

Last time was 23 December 2019 it seems….. and then it was £36.00 including free home delivery

This week I ordered a new spare bottle, as the welding @nickwheeler and I were doing on the various parts of the car would use up the existing bottle.

This time it was £50.40 for a refill. Feels expensive but I suspect it is what it would cost with all the price increases seen recently.

I also ordered 25 Bosch 1mm cutting discs, just under £15.00 delivered.

When I got in tonight from Woolwich the rubber hose needed to connect the extended air intake as well for £5.29 delivered.

Small items helping get this build further along.



Friday tomorrow.

Saturday will be mostly garage time and progressing .

Sunday I am hoping KevFromWales will make it here for a visit and to collect the MX5 shell .

Still enjoying this all.

[Grizz1963]

Did a quick job after work tonight.

Been a hard week tbh.

One year in the making…………

Tinted the trucks windows.


BEFORE



DURING



AFTER



TESTED WITH A LIGHT METER.

LEGAL.

DRIVERS SIDE



SCREAMING SIDE



PRETTY PLEASED TO BE HONEST.

ROLL ON THE WEEKEND.

ROCKIT WAITING.

[Grizz1963]

So after the indoors work and moving the MX5, I headed down to the garage.

A frw small time consuming jobs were waiting.

After unpacking al the stuff that came off the car in the first place, trying to find the fender brackcets I gve up.

Started to make some brackets, using some steel I had in my pile.



A pair needed of course.





Followed by a pair of radiator brackets, slightly more complex, but done soon enough.



Top of the radiator has rubber bungs to fit these holes.





Happy with that.



Decent remakes and functional.

Lets see what @nickwheeler has to say about them, he is the QC here.




While out there with the cutting disc, I decided to cut the numbers out too from the carcass of the donor, they will be welded onto the chassis later, just for the record.



Inbetween George the cat came down twice to check up on me.


Tomorrow I have the whole day to myself to carry on with the build.

Sally will be at work most of the day, starting at 06.00

Crappy job ehhh.

[Grizz1963]

After the brackets, I had another coffee.

Thanks to Nick, I drink more coffee now.

It allows me time to reflect for 10-15 minutes when progressing ideas.

Then back to the build.

Engine bay next.

It is pretty untidy.

Found some used, scrap aluminium to make a blanking plate.



Ductape, gotta love it.



Removed the heater pipes’ access, and copied the holes onto the plate.

Then got the template Nick had made last weekend and transferred it.

Drilled, jigsaw and a regular hand file to shape.



Holed.



And test fitted.



Then removed the grommet again and turned it inside out after cutting back the loom tape.

Filled with horrible gloopy black foam stuff.

Unpicked most of it.



Then drew the grommet over the lumpy bit to the next loom junction.

And it seems a perfect length to get to the firewall.

Tomorrow morning I will fit the grommet again and screw the plate into the firewall with a bit of sealant around the edges to seal it well.



At this point I made a quick escape and closed the shop so I could come in and spend a bit of time with Sally and make dinner.

She had done a 9 mile fast walk this morning with Sl in preparation for the Moon walk they are doing in May, for which she has managed to collect £700.00 so far, so she was tired and would not cook for herself.

When I came in George, the cat I do not have, had spent most of the day on my chair……..

King George?



Tonight I am waiting for KevFromWales to get here to collect the carcass of the MX5 donor.


More progress tomorrow I hope.

Tired tonight.

[Paul Y]

Lots going on as usual Ryan.

Burnouts and ice cream by 1st March then…..

P.

[Grizz1963]

Originally Posted by Paul Y

Lots going on as usual Ryan.

Burnouts and ice cream by 1st March then…..

P.

Wouldn’t that be cool Paul.


I think there are so many time thieves in this build.



Have a list.





So the weekend has been……

Today I had planned on doing a load of smaller tasks that would get me moving along the list that @nickwheeler had previously created as a guide.

I like lists.


Thanks Nick for creating this.



Rezin Rockit
Jobs List

I’ve broken these down into Mechanical, Electrical and Body. There will of course, be some cross-over as to what should be where.

Now that most of the major fabrication - engine and gearbox mounts, scuttle support- is done, the remaining jobs are each much smaller, but they ought to be done in a considered order so that they don’t have to be re-done. Like the old joke about how you eat an elephant: one bite at a time. Getting the car running and driving is the objective.

To that end, jobs will be tagged with a priority and difficulty rating as follows:

High Priority - large job, that will enable others to be completed, or parts sourced
Medium Priority - smaller job, with consequences
Low Priority - small job, can be done at any time

Difficult - time consuming, orneeds extra parts planned and acquired, or tools, or skills, or more hands
OK - achievable with available parts, or minimal time
Easy - quick job, needing little equipment or expenditure


Your assessment will probably differ slightly!


Mechanical

Steering Column: Fit column, make connecting shaft, make weather tight

High priority - can only fit in one place, and will affect other placements
OK difficulty - shafts need turning and welding inside sleeve

Clutch Pedal: Adapt Ford pedal to hydraulic, fit master cylinder, connect to slave

High priority- requires mods to brake brackets and bulkhead
Medium - placing is a two person job

Throttle Pedal: Fit Mx5 pedal assembly, and use casting as pad.
High priority - needs to attach to bulkhead/pedal bracing

Throttle Cable: Longer cable with Mx5 fittings required
Low priority - can’t be done until pedal is fitted
OK - needs parts sourced, but easy to do

.Propshaft: Hybrid Ford/Mazda shaft required to custom length
High priority - last big mechanical part, car won’t drive without it, might take a while
Easy - cheque book job!

Brake Master Cylinder Inspect and improve as necessary
Medium Priority - easy job, but needs doing before car is drivable
Easy job - standard part, readily available

Hydraulic Lines: make new brake & clutch lines as appropriate
Medium priority - needs pedal fitted, but best done before other parts fitted
Easy job

Radiator: Make brackets as required
High priority - mods to fan and hoses will be required
Easy job

Cooling Fan: Mx5 fan needs modifying or replacing
Medium priority
OK or easy



Cooling hoses: modify radiator, expansion and heater hoses as required
Medium - needs radiator and other parts fitted first
Easy

Engine Service: New plugs, oil, filters, cam belt etc
Low priority - not to be touched until after it’s running!!!!!!!!
Easy

Fuel system: Fit tank, fuel pump, filler, pump filter and pipes
High priority - probably the biggest single job, affects other parts
Difficult - parts choices, fitting, fabrication etc

Gear Lever: Needs extending/cranking back to suit driver
Low priority
OK

Exhaust: Make new system from downpipe back
Low/medium - needs fuel tank in place
OK

Airbox/Intake: Fit airbox and modify trunking as required
Medium priority
Easy

Rear Wheels: Sort out correct studs/nuts and fit larger tyres

Low
Easy


Electrical

Main Loom: Fit to dash support, connecting to fixed parts and mounting components as required. Route front legs through bulkhead, and along inner wings then modify to match components as necessary. Route rear section along driver’s sill.

Medium
OK

Power Loom: Connect to starter etc, route along chassis to rear, connect to fuse box & distribution block

Medium
Easy

Engine Loom:Route through bulkhead and seal. Mount ECU to dash rail.

Medium
Easy

Rear Loom: Connect to front loom, route to components, secure

Low
OK

Battery: Build and install battery box

Low
OK

Wipers: Design and install - Either OE Land Rover, generic screen mount or re-engineered through scuttle

Low - not needed for car driving
Depends on decision



Body

Roll Bar: Source and fit. Make new chassis mounts

Low priority
OK, once part is on site!

Dashboard: Design, build and install dashboard

Medium - not required for car to run
OK

Bulkhead: repair all redundant holes

Low
???? - glassfibre work

Floor: Strengthen as necessary, adapt for new Roll Bar
Low
???? - glassfibre

Gear Lever: Lever hole needs moving forward and finishing

Medium - needs doing before dashboard
Easy

Windscreen:Modify and fit

High - best done before the underdash electrical work
OK - some fabrication and fitting required

Seatbelts: Need Roll Bar in place

Low
OK



Job Order

Steering Column and Linkage

Pedals

Wiring looms, concentrating on getting the engine working

Hydraulic lines

Fuel system

Propshaft

Exhaust

Roll Bar

[Grizz1963]

After a rubbish night I was out in the garage early.

Weather forecast was for a lot of rain, so I needed to beat that, and the chill.

So I carried on with the firewall plate I had made up yesterday, and the next planned job was to cut the holes in the firewall for the two side wiring looms to come through over the fenders.

Then Nick arrived.

Coffee, chat, planning and some gift exchanges.

He also forgot the sleeve and two parts of the Ford and Mazda steering shafts last week.

Plan is to turn them both down on the lathe to fit the tube, drill some holes to weld up after getting the total length right, followed by ensuring it all will work to,wrap,the steering up.




After KevFromWales failed to materialise by 01.00 this morning, he eventually made it to my place by 1.00pm

Kev and Nick hit it off and gassed for an hour before we loaded the MX5 onto Kev’s trailer.

A few mugs of tea, cookies and Kev was off on his return trip to Wales.



Once loaded the coal roller headed out.



Then Nick and I went back to work.

Loads left to do.

[Grizz1963]

So next job you,say.

I had hoped to sneak an hour in during the week, but work just was relentless, and by the time I got home in the evenings, I could not be bothered once I had dinner and sat down for an hour with Sally.

So Sunday was earmarked for that as well.


Looms laid out roughly by @nickwheeler.

Hole saw at the ready and off we went.



With the position of the gas pedal or is it petrol pedal, or throttle…… and its backing plate, there was just enough room to drill out for the large grommet and loom plus various plugs to get through on each side.



Done.



Nasty fiberglass filed back a lot to tidy up.



Both exits ready.



Inside view.



And all three looms in place.

Loads left to do still, but progress for sure.



Nick had been at me since day one when we stripped the MX5 to add a heater to the Rockit, which I kept declining.

So this week I was looking for the throttle cable and pedal

When I decided to pull the original heater/blower out of a box of bits.

Nicks face was like a kid at Christmas, and of course between it, and the original, the Mini blower that this would have been originally, fitted like this.



I may be thankful in the long run when I drive it in November…… or March if the heater keeps my feet warmer than a penguins tail.

We had agreed to an early stop, by 5.00pm as I wanted to cook Sally a Valentines dinner (nothing that special) as she had been at work all day.

But typical Nick, and me for that matter…….

The rear lights and fuel tank loom came out to also be laid out and arranged…..

Last of the nightmare pile of wires.


We should have weighed the loom, just as a matter of interest.



After this and now well after 5.00pm we also stood discussing one of Nicks best ideas that came to him while walking around in Rochester Cathedral.


Relocating the battery from the rear into the engine bay, which then also included setting out the airbox, MAF and connecting pipe.


So a bridge needs to be built, behind the engine, over the gearbox, with a battery tray. (Mocked up roughly in the photo) as well as a bit of a riser for the airbox.





And that was how my weekend ended.

More jobs added to the list of fabrication jobs.

But both of us grinning madly as a bunch of jobs of the list are now partway done.

Monday……..

[Paul Y]

Good work as always Rian but, a very small but, why have you go the engine loom going through the bulkhead at such a height?

Also... Why not fit the battery where the air box is and then run the airbag through into the cabin so you get all that wonderful indication roar!

Will drop over in the next week or so to collect the cab lifter so looking forward to my first ride out in it....

P.

[Grizz1963]

Originally Posted by Paul Y

Good work as always Rian but, a very small but, why have you go the engine loom going through the bulkhead at such a height?

Also... Why not fit the battery where the air box is and then run the airbag through into the cabin so you get all that wonderful indication roar!

Will drop over in the next week or so to collect the cab lifter so looking forward to my first ride out in it....

P.

Thanks Paul

partly replicating what was in the MX5 and partly working with the tight looms.

Induction roar…… nahhhh.

You also have a blasting pot here.

And a Jeep Cherokee fuel tanl.


Who knows what else.


Craig should be here on Saturday morning, en route to Shropshire from Guildford.

[Grizz1963]

Report tonight from Nick Wheeler.

He took the steering parts with him yesterday………


Reporting thus tonight.



Pictures aren't in any particular order:


Knocking the Mazda shafts apart because I can't get the assembly in the lathe



Knocking the Mazda shafts back together



Mazda shaft in the lathe



New shaft turned down, with the joining sleeve



Sleeve slid onto the new shaft



All 3 parts slotted together; we need to shorten the new and old ones slightly to get the right length, and weld the sleeve to both




And an explanation:

We need the joint that matches the steering column and one that matches the rack to be joined together via a longer shaft.

the new shaft and black u-joint are the standard Ford/European 9/16 23(I think)spline fittings. Sleeve is thickwall CDS that is almost 9/16 bore and about 150mm long for a strong connection. Certainly stronger than the original modified Cortina shaft that seems to be a piece of rod butt-welded in between the original ends.

The Mazda shaft doesn't use those UJ fittings, and is different at each end for some reason. 

I turned about 100mm of the new shaft down until it was a slip fit into the sleeve.

The Mazda shaft was too short to fit in the lathe with the UJ fitted. I wasn't sure how the parts were joined; the UJ is attached with a staked pin, and it turns out the two shafts are just splined inside each other which is probably for crash protection. I knocked them apart and turned some of the loose shaft down to match the new one. Then I knocked them back together with a new O-ring.

I still need to drill some cross holes into the sleeve for some belt-and-braces plug welds.

We will shorten each shaft by about 20mm, fit the relevant UJs to the column and rack and weld both shafts to the sleeve.

That will complete the steering, and allow us to fit the other components that need to go in the same area.[/quote]

[Grizz1963]

So with a few ideas bouncing around in my head, and @nickwheeler doing a CAD design, I had a few routes to go, all based on available materials in my pile.

So I made a rough cardboard replica of the battery.





Nick did this design and a few others.



So I started with a 50mm x 5mm steel strap, bent and cut to bridge the gearbox.



And made up a small frame that the battery tray fitted into.



Welding next.



Looks like a nice fit.



Mocked up with the battery in place, clamp in position.

The feet will only be welded once the rivnuts or captive nuts are drilled and fixed in.



And finally, bracket in place.


Pretty pleased with this outcome.

There may be some gusseting to be done.




Next job will be to create a stand for the airbox to create a raised platform.


Onwards…….. in the words of @pauly

[Braunschweiger]

Wow, great progress, you two make a great team.

[Grizz1963]

Two small reports……

Nick said:

Could I suggest 8.5mm holes in each end of the brackets, and matching 12mm in the rails? I'll provide some weld in threaded bungs, as I'm not convinced about rivnuts for this job, and we need at least two good earth points.


4 M8 threaded bungs to weld into 12mm holes in the chassis rail. We will need to drill clearance holes in the body for it to float over the bosses. These will also make for good battery and starter grounds.

I'll make some more, but tapped M6 for the light grounds at each corner. But I'm due at a ringing practice so that's a job for tomorrow.





So battery strap V2.0

Bypassed the sleeve, though I still like it.

So as @kevins said…….

Webbing.



Add some brass eyelets

And a hot punch.



Holey Moley.



Brass eyelets added.



And then a lightweight mock up.



Now we just need to wait for the vegans to object to the tightened nuts.

Just teeeeaaazzzinnng.

May still go back to the sparkly option ⚡️⚡️⚡️⚡️⚡️⚡️⚡️⚡️⚡️

Thursday…..

Weekend soon.

Garage time.

[Grizz1963]

Lunch was a couple of Ginsters chicken and Bacon meat pasties.

First time I had them, and enjoyed them.

One of todays jobs with the body coming of again as well, was getting the battery bridge finished……….

Followed by a support for the airbox.

And most importantly for @Nickwheeler and I would be getting the steering sorted.



Lifting the body again meant a few Riv-Nuts could be fitted and one knocked out and replaced.

This was to ensure the body mounting points to the chassis were all secure and present.

So the Riv-Nut tool.









PITA body of and on.



Next up was to refit the breathing system.

First job was to cut off the resonator, prepare for more noise.



Also refitted the second time was the steering rod.






So the steering is back, for the first time in months.

VIDEO:

https://youtu.be/29bKFUqFDok


Nick left at 4.30 sharp for a5.00pm meeting.

And I cleaned up down at the garage.

Progress again today.




So the weekend is pretty much over again.

But very satisfied as we managed to get a few jobs progressed andmactually the steering is ticked off the list.

Thanks for checking in.

[realvc]

That is a very nice battery tray you have built for the RR.

[Grizz1963]

Originally Posted by Braunschweiger

Wow, great progress, you two make a great team.

Thank you Harald.

It is great when you do find people with a similar work and creative ethic.

Originally Posted by realvc

That is a very nice battery tray you have built for the RR.

Hi Vince,

Thanks a lot.

Pretty pleased yes.

[Grizz1963]

Power failure since 11.00 Friday morning .

Two power pilons down.

Not sure when we will have electricity again.

Means @nickwheeler and I had no power down at the garage tonight.

So all progress was non energy dependant.


Also no heating in the house.




Storm Eunice still tearing up the world outside.

[Grizz1963]

Part of yesterday’s zero emissions progress was another one of @nickwheeler ‘s crafty longterm ideas.

The Mini heater box, fan and matrix from the original kit car was one speed and no more than lukewarm.

Where as it was mentioned that the MX5 heater was a furnace and also 4 speed

So dismantling to the sum of its parts, discarding 50% of the useless bulk and redesigning the blower box, exit vents and matrix positioning could lead to a win.

So while I searched for a ready made solution (think random discarded containers) Nick grabbed some pizza cardboard box, scissors and masking tape.

He won………..

Further fine tuning and fitting needed.

Also the transmission tunnel needs a hefty chunk of surgery and sculpting to allow the blower to fit under the scuttle and behind the firewall.

More added to the list of tasks.




Today the power is still out and no prospect of a repair today either. A freezer load of food to be discarded.

Not impressed with that at all.

But apparently we are not a priority.

So this morning I cleaned up the carport area after the storm yesterday.

Of course the wind and rain waited just for that point where I was done, to start all over again.

So now it is cold, wet, windy and raining outside.

But earlier on I did make it down there to remove the front wheels as I want new valves fitted that were not done when the tyres got fitted as the plan was blasting and painting.

While I was there I decided to clean up and reset the tie rod ends as the front end was way out of line.

New short term lodger John came down when he got up to see what I was up to.
He is a Trike rider and builder having a full strength V-MAX based trike. He lost a leg at at age 24 in a motorcycle accident when he was T-Boned and had a high thigh amputation.
He works as a driving instructor and has a keen mechanical eye.
Nice guy to have about too.

So an extra pair of hands to hold a twin pair of vice grips on the steering rod.

I also cleaned up the threads on both sides so the steering toe in could be fine tuned once the car is completed.



Once the threads were done and reassembled I fitted the space savers so the wheels can get taken to the tyre shop.



Military spec?

Rake.



Now sitting indoors with a drink and a fire warning my heatless, cold, dark house.

Anyone know a main grid electrical man or woman.

Get me some electricity

And internet.