Purchased in July 2021 at the same time as 4762. Both cars were completely disassembled with parts comingled. Additional “before” pictures can be seen in the section for 4762 Chocolate and Cream.
Start with the engine:
clean all tapped holesnew cam bearingspolished crankshaftSealing pushrod tubesAssemble headNew type rear main sealFitting new rear main seal using mandrelNew timing belt tension springinspect and recondition oil pumpsoil pump installedBottom ends finishednew front sealalmost donealmost doneNew high volume water pumpnew sleeve on front pulleynew pressure plate and new discmodify throw out linkage, See: Modify +4 Clutch Linkage” elsewhere in this websitebellhousing fittednew rocker shaft and bushingsrockers on new shaft; old shaft shownnew rocker shaft installednew distributornew distributor installednew Lucas alternatorinstall Alternator conversion
And then make the new chassis:
new chassis rails with reinforcementsthree crossmembers addedrails bent, front crossmember fabricated, pedal set fitReality Check; new chassis stacked on old. Rust paint on inside crossmembersbottom plates welded on crossmembersCheck fit front subframeweld spring brackets and check fitadd spare tire frame and bumper brackets fit damper bracketsform exhaust cutoutCheck fit engineCheck fit enginefinished chassis in etch primersilver ImronChassis in primer surfacerChassis in primer surfacerBlack ImronBlack Imron
Start Assembling
gas tank, springs/differentialmotor mounts, bumper brackets, dampersDampers & links, damp coursenew kingpins and bushingsnew dual master cyl and completed NiCu brake linesnew pistons and sealsrebuilt caliper, new hose and damper blade installedne front dampersOften Overlooked: driveshaft ends have alignment arrows driveshaft installednew valences painted and installednew “dummy” regulator, fuse box and additional fuse box for new stuffRubber matt and Plus 8 heater installednew battery; one-shot plumbing, horn
Some New Sheet Metal bits…
layout valencesmaterial cutoutroll beadsbend bottom flangestretch bottom flange to match chassisstretch bottom flange to match chassisbasic valence check fit to chassisstart turning top flangefit to wingfirewall in workcheck fit firewallcheck fit firewalladd toolbox parts to fixturecheck fit toolboxroll beads on new valencesadd flangefinished rear valence for 2 carsnew toolbox and battery traynew parts in Imronnew toolbox in Imronfillers under thresholds ompleteLeft Spring cover remade to maximize seat travelNew Right Spring Cover
Wheels…
wheels in primeGuess what color this car will be…5 New tires
Interior Woodwork
2 1/2″x 9′ Slab of Caro Walnutold dash and walnut blank (to be resawn for three dashboards) Jig saw at angle to cut glove box door at a taper finished door does not drop through (0 kerf)instruments fitted, ready for finish second application of clearcoat.
Rebuild SU HS-6 Carburetors.
HS-6 carbs with original short manifold and rebuild kitsNrw bushings, shaft and butterfly installedRear carb fully rebuiltnew SS shafts and new levers on turned SS heat shieldinstalled on engine
And the Body…
Marine Mahogany inside panelsNew Ash wheel archesNew wood front section reusing a few good orignial bitsnew sillsparts rear bulkhead in workfinished rear bulkeadCheck fit new rear sheet metal to bulkheadCheck fit new rear sheet metal to bulkheadwheel arch “shoes” finishednew rear panel installeeset centerlineThresholds fitted epoxied and screwedoriginal scuttle trimmed at hinges and fittedmake and fit door postsrear wood finishedseats fitteddoor framinng in workdoor framing in-workbody frame finished, seats ready for upholsterybody frame finished (Don’t let anyone tell you it’s easy.)
Body Tub Sheet Metal
Scuttle installed with new steel bottoms welded one-piece rear panel in workwire formed edge finishedrear panel installedrear panel: no rippels, zero body filler requiredbegin quarter panelalmost doneleft side formedhinge details. striker, and dovetails finsihed. Door fittedleft door finishedright door finshedNew lights, script and lower valence fittedDoor drip edge soldered onHood bows repaired and fittedHood bows in position
Instruments
Engine turned stainless steel dash panelinstruments fitted, Dash ready for finishoriginal instruments before rebuildSpeedo, Tach, and tank unit rebuilt by West Valley InstrumentsAmmeter converted to Voltmeter, Temp guage upgraded, Gas and Oil P inspected, Everything reprinted. Beautiful work by West Valley Instuments
Wiring
schematic; old and new circuitsStrip, clean, repair, and add new circuitsTrial installationHarness complete
Sidescreens
Decided to adapt a pair of aluminum sidescreen frames from a later model four seater. The advantage being acrylic window panels that slide open and that you can actually see out of. No good deed goes unpunished. It was a lot of work.
Fit aluminum frameNew Stainless Steel struts in workone pair of SS struts ccompleteLeft Side Frame With StrutsFit new aluminum lower panelNew acrylic glazing installed in both front and rear screensVinnyl covering complete and new rubber sealsRight side completeRight side completeLeft Side Screens Complete
Seats and Upholstery
I have adapted Sparco brand seat slides on three previous four seaters and my own DHC. They work well and make it easier to adapt to different drivers. My back will simply not tollerate the original coil springs installed by the factory. I started using proper upholstery springs many years ago. They are vastly more comfortable particulary for longer journeys.
Upholstery Spring MaterialFabricationng new springsCompleted seat frames with adjustable head restsCompleted seat frames with Sparco Seat slides installedSeats Fitted with Foam and Webbing installedCanvas Covering onn Rear Seat FoamCompleted leather seatCompleted leather seatLeather front seat backs and cushions finishedNew Edge Bound Carpets
Cowl, Bonnets, and “Final” Fitting of Body Parts
factory new wings fittednew wing lights located and fitted
Bonnets
These bonnets are a special case. After a day of picking and filing I’m coming to a tough decision: Continue straightening the originals and finish with polyester body filler (normal body shop approach) OR make new? Body filler is great stuff. I use it but very sparingly. I don’t like using it on parts like bonnets that flex. But making a new bonnet is a lot of work. Then again, a new bonnet has no filler and is straight. Tough call.
original bonnet after a day of raising dents and straightening
Make a New Bonnet
Can’t overemphasize the need for accurate patterns20ga CRSlayoout patterns on steelstarting second bend at hingefirst bend for hem at rearcompleted double ham ar rearFirst check fitcheck fit after begining bendbend comple fitted to cowl at frontlocate and fit latchesWire rolled bottom hem doneRight Bonnet with bottom wire rolled hem fittedlatches fitted to car. Only louvers left
