DDK - Die Deutschen Klassiker

Pump looks good - who did the rebuild?

Hi Gavin - Fred Pentecost at Tower Bridge..

http://www.towerbridgediesels.co.uk/

Hi Kieron

Hows the project going? still "ignoring the cost" or being constantly reminded by the wife as I am...?

Adam

Hi Adam - I'm counting down the weeks to the car going off to Barry, looks like it will be with him towards the end of April. I was interested to see that Jamie used a 'lowloaded' van to move his shell rather than lashing it to a trailer so I'm looking at the options before moving mine. I visited Nick at Redtek recently to discuss the spec of my engine, unfortunately it seems that my cams,throttle bodies and rockers are all u/s so I'm on the search for some replacements and I may opt for 'S' cams which Nick says will push the BHP up a bit.

How's yours coming on, have you got your seats sorted yet?

Hi Kieron, good stuff. It all comes round quick doesnt it. My car will be with Barry at some point this year so am trying to get the engine sorted now to ease the pain later. Nick really knows his stuff and I wanted to use him but opted for Redline as literally 5 minutes from my house and did a great job before CLM... one of the problems of being from the north... hopefully rest of motor good!
Seats not sorted and the daft money people are wanting for seats Im going to get the ones I've got refurbished I think, bit of character with the car (thats what I'm telling myself). To be honest I'll get rest of car done and seat can wait till I save up as a seat is a few panels!
Please post more pictures of the car whilst at Barrys and good luck!
Adam

6. Removal of the rear quarters.

Excitement is starting to build as the car goes off to Barry at the end of the month. Thought I'd give him a hand so I whipped off the rear wings yesterday...

Hi Kieron
Exciting times...! Where did you purchase the 'dolly' from to move the shell, mine is currently sat on a flat bed trailer which is not ideal...
Good luck end of the month, please post Barry photos of progress!!

7. Off to East Sussex.

Next stop Barry..............

....let the fun begin!

8. Final assessment before Barry fires up his welding torch.

As Darren says let the fun begin...

....the previous owner had provided pictures of the car on a jig so I was hopeful all would be good but wouldn't really know until Barry had it on his jig. After a few minutes walking round we had decided on a slightly modified plan of attack and compiled a supplementary list of parts including a complete o/s inner wing, n/s and o/s 'A' posts, n/s/f and o/s/f chassis legs, a complete floor (front & rear halves) and front screen bottom corner repair sections.








Nearside measures 5mm short on the adjustable slider.





Whole front over to the left, although much of this is due to the bent torque tube: the starting point with mounting the car is always the tube, so if this is bent it can send the whole car out as far as the jig is concerned.







Offside short by 5mm, on this side it is genuinely short, as the torque tube was low on this side, but not bent fore and aft.




Offside front suspension mounting.



Kink to rear of battery box.





Buckling to rear of offside front inner wing.





Filed strut tower, a particularly nice touch I thought.






Kink to RH chassis / inner sill near base of A-post



Hole to RHF inner wing.





Kink to pedal box area.







So I left Barry setting up his stretching equipment while I went away to order more parts...

9. A few more reference images.

Offside torque tube bracket, note rip in metal above 'stud' in second image.





O/S/R engine mount, not shown is the fact that rear is about 4mm low (as is usually the case).


N/S/R engine mount.



N/S/R torque tube bracket.







Diagnosis - bent torque tube!

10.1 Pulling the shell back in to shape (rear).


Some images showing Barry getting the shell back into shape...

With the height corrected and the first torque tube pull completed, the O/S torque tube outer bracket fits nicely, note blurred picture trying to capture fact that tube bracket centre is easy sliding fit.






All bolts fit by hand.





March of the brackets! From one to three, gaining on it now ....





Dozer beam set up to clamp to jig base. Dozer has 10 ton capability, but can be levered to give about 12 tons.




Dozer positioned to give side-n-down pull.





Hmmm, not there yet ....





Going up at rear using 10 ton Porta-Power.




L/H/S - nice free peg, no load on it.



Same on R/H/S



rear sorted...

Oh so interesting, thanks for posting that lot, keep them coming.

10.2 Pulling the shell back in to shape (front).

Barry now moving to the front.....


Whole of rear and centre straight and resting on jig without stress.






LH slider (rack mount) still a bit high, although position better.






Using vector pulley to get more or less vertical pull downwards we're now down to 2mm error, which Barry will return to later.







Tugging RH side.





Over-pulling to allow for spring in shell.





Needed still more, so Barry doubled to dozer with the porta-power to give 20 tons available.





Barry finally achieved the stretch he was aiming for


which resulted in this...
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Note... no bolts, no stress.






Nearside.

Fascinating - thanks for sharing