The 1960 Zody Gasser

[1960Zody]

It’s good having mates,
To start off I want to say thanks to Darren for the loan of the gennie and to Jon Hughes without whom etc…

So, we started off with a complete but crusty gasser, a lockup with no power, a borrowed genie and some steel.
http://usera.ImageCave.com/1960Zody/Zodiac/Zody2.jpg

First thing was for Jon to start making the replacement inner sill section from a pair of brand new pattern sills
http://usera.ImageCave.com/1960Zody/IMG00032-20090305-1304%20(Small).jpg

While that was happening I gutted the interior
http://usera.ImageCave.com/1960Zody/IMG00033-20090305-1537.jpg

Out with the angle grinder to start cutting the rot out of the floor
http://usera.ImageCave.com/1960Zody/IMG00037-20090305-1623.jpg

Well, that’s not such a bad hole for a 49 year old car
http://usera.ImageCave.com/1960Zody/IMG00039-20090305-1629.jpg

I dunno, you go off to by some crisps (Cajun Squirrel) and he goes all psycho with the grinder 
http://usera.ImageCave.com/1960Zody/IMG00040-20090305-1649.jpg

OK, so the hole is a lot bigger now, also a great chunk of the sill and the strengthener have been removed as well
http://usera.ImageCave.com/1960Zody/IMG00041-20090305-1700.jpg

In this one you can see how much eventually came out and the ‘several’ previous repairs that have been done over the years
http://usera.ImageCave.com/1960Zody/IMG00043-20090306-0942.jpg

Another shot from inside the wheelarch showing the bottom of the sill cut out
http://usera.ImageCave.com/1960Zody/IMG00046-20090306-1125.jpg

The inner wing is in good condition though, pity it’ll be cut out to make way for the fenderwell headers.
http://usera.ImageCave.com/1960Zody/IMG00047-20090306-1126%20(Small).jpg

After removing both the wing and the door the final bit of rot was found.
You can also see where more previous repairs were done over the years.
http://usera.ImageCave.com/1960Zody/IMG00048-20090306-1214%20(Small).jpg

http://usera.ImageCave.com/1960Zody/IMG00050-20090306-1238.jpg

And that’s where we stand at the moment, having found out that 5.5KV gennie is not man enough to run Jon’s Mig
So we’re waiting for Jon’s Pop to be bought so the gasser can get into his garage where there’s power.

Unless someone has a space in a corner with some power to plug a welder into???


And this one sums up the essence of Hot Rodding, If you see what I mean.
http://usera.ImageCave.com/1960Zody/IMG00031-20090305-1252.jpg

Thanks again Jon and Darren.

And stay tuned for the back end rebuild.

[koolkev]

Hey , cool , look forward seeing it in a loooong line up of nose bleeds at a show soon ! ! :D

[langysrodshop]

Do i recognise that front axle ???

[1960Zody]

Yup, It's a 'Langy'...
And it's the one part responsible for where I am now, If Joe hadn't bought it from you and sold it to me I'd have just resprayed the car, ran it for a season and sold it on.. :-)

[Jonny69]

Here are some more pics in no particular order.

The inner sills were a bit grotty and someone had jacked the car by the sill so it was all pushed in. This is a good time to deal with little bits like that.

I'll start with the important bit, the car, up on stands:

http://www.dropfiles.net//files/319/garage/IMG_3670.JPG

http://www.dropfiles.net//files/319/garage/IMG_3671.JPG

Oh and the engine is important too:

http://www.dropfiles.net//files/319/garage/IMG_3701.JPG

This is now in an odd order because I took the pictures backwards, so here's starting with the second problem area on the car.

The second problem with the car was a bit of grot in the floorpan on the drivers side. Cleaning it back revealed a previous repair and only more grot to have to weld the inner sill to. So I hacked it right back to put in some fresh panels. Here's the new hole in the floor and removed inner kick panel on the A pillar:

http://www.dropfiles.net//files/319/garage/IMG_3676.JPG

The strengthening panel is good so we just have to replace the inner kick panel with this:

http://www.dropfiles.net//files/319/garage/IMG_3677.JPG

On the A pillar outside it's a bit snotty on the drivers side. Passenger side is already repaired but here needs attention:

http://www.dropfiles.net//files/319/garage/IMG_3680.JPG

http://www.dropfiles.net//files/319/garage/IMG_3681.JPG

Yuck. I've made this panel to start to rebuild it with:

http://www.dropfiles.net//files/319/garage/IMG_3682.JPG

And looky here behind the door, it needs seeing to as well:

http://www.dropfiles.net//files/319/garage/IMG_3683.JPG

I waved my magic wand and my snips and hammers danced together like in Fantasia and made this:

http://www.dropfiles.net//files/319/garage/IMG_3684.JPG

http://www.dropfiles.net//files/319/garage/IMG_3685.JPG

Er, this is the bit that goes inside, probably should have showed you that before:

http://www.dropfiles.net//files/319/garage/IMG_3687.JPG

Back inside the car again the outrigger is rotten where it meets the inner sill so that's been lopped off:

http://www.dropfiles.net//files/319/garage/IMG_3688.JPG

And it is to be replaced with this natty little outrigger I made:

http://www.dropfiles.net//files/319/garage/IMG_3689.JPG

Fits on like a glove and the floor will be supported by it:

http://www.dropfiles.net//files/319/garage/IMG_3690.JPG

Now onto the floor, front section is curved and the lip on the edge goes downward, then there's a second rear section where the lip goes upward. The grotty bit managed to pas across both bits so I have to make two repair panels for one hole. Well I don't have to but it'll look nicer and more original when it's done. Here's the front one, lightly curved:

http://www.dropfiles.net//files/319/garage/IMG_3691.JPG

And in place:

http://www.dropfiles.net//files/319/garage/IMG_3693.JPG

Now onto the sill itself. The car has been re-silled already to a satisfactory standard but the ravages of time and neglect mean it needs doing again. Only the front and back inner are gone so I'm not taking the whole thing off, just sections. Repair panels are made from an inner sill panel. They aren't the whole sill, just a bit of it so I've had to form the end myself. Not too hard to do and this is what it looks like:

http://www.dropfiles.net//files/319/garage/IMG_3695.JPG

http://www.dropfiles.net//files/319/garage/IMG_3696.JPG

Under the car you can see the munched part of the sill. The bent bit is the middle sill, yup, it was pretty mashed in to get that far. You can see two cuts in the outer sill which I have made either side of the dent so I can pull it back into shape and weld back together:

http://www.dropfiles.net//files/319/garage/IMG_3698.JPG

Inner sill drops into place pretty much like this:

http://www.dropfiles.net//files/319/garage/IMG_3700.JPG

And this is how we left Noddy's Taxi. On the right you can see the two sills:

http://www.dropfiles.net//files/319/garage/IMG_3702.JPG

Because of the welding issue the next time you see this may be at Jonny69 Towers where we'll fire up the bzzy zappy sparky thing and glue the new bits on with molten metal.

[cabby]

Nice bit of tech chaps, its nice to other folk helping out in peoples builds, we`re not all born with the skills!

Well done Jon and Steve

[1960Zody]

Nice bit of tech chaps, its nice to other folk helping out in peoples builds, we`re not all born with the skills!

Well done Jon and Steve

More like well done Jon, Cabby...
I just looked and pointed, wire brushed the floor and unbolted things....
Much to learn.. :-)

[vince-305]

Its coming along well m8

Wheelsday or bust eh ?????

[1960Zody]

Its coming along well m8

Wheelsday or bust eh ?????

At the moment, unless I can find somewhere to do the welding, or Jon sells his Pop it's probably bust m8

[cabby]

Steve, how are you getting it to Jons??

[1960Zody]

It'll be a recovery company.
Jon has one he reccomends

[cabby]

Not wishing to step on Jons toes but if you want you could bring it to mine, I cant get it in the garage to store, but can be kept safe outside the garage over night under cover (at the back of the house) up to you mate?

[luke-the-drifter1953]

hi steve, i met you at the swapmeet wiv my mate dave who bought the pop wheels of you. just been lookin at your car and it looks well cool as a gasser. what suspention an steering are you using as id like to put somethin like that on my consul

[Klunk]

http://www.dropfiles.net//files/319/garage/IMG_3680.JPG




I see the wheels I gave you fitted then....Cool. I have another pair available too.

[luke-the-drifter1953]

good inner wings for a mk 2 mate. most i have had have had to have repair to them

[AL]

It'll be a recovery company.
Jon has one he reccomends

Have you had a quote, where's it going from & to, I may be able to do it.

[1960Zody]

hi steve, i met you at the swapmeet wiv my mate dave who bought the pop wheels of you. just been lookin at your car and it looks well cool as a gasser. what suspention an steering are you using as id like to put somethin like that on my consul

Hi Luke,
The axle was built by Steve Lang some time ago, but basically it's got a Granada (I think)Rack mounted behind it to minimise bump steer.
The original column is intact in the car up as far as where it comes out of the firewall.
From there the steering box was cut off and a UJ welded on with a sliding joint drop arm going down to the rack.
Mk 2 Granada hubs and brakes, parallel leaf springs and a pair of Pete 'n Jakes Hot Rod shocks, chosen simply because they're shiny and they fit... :-)

[1960Zody]

Not wishing to step on Jons toes but if you want you could bring it to mine, I cant get it in the garage to store, but can be kept safe outside the garage over night under cover (at the back of the house) up to you mate?

Like I said at the start of this thread, it's good to have mates...
I'll put arrangements in place Cabby...

Thanks

[1960Zody]

I see the wheels I gave you fitted then....Cool. I have another pair available too.

So much easier to push around now...
And it gives me some 'spraying' wheels if you see what I mean Tony.
Test fitted the Cobras I got at the swap meet and they look like they're gonna be perfect.

[1960Zody]

Have you had a quote, where's it going from & to, I may be able to do it.

Hi Al,
It will probably be going from Abbey Wood to Cabby's.
Not sure where Cabby lives though.. :-)

[Klassicdave]

Hi Steve, I've had the wheel blasted I bought from you and will be painting them this weekend. Zody gasser looks real promising, keep the pics coming mate.

Dave

[1960Zody]

Hi Steve, I've had the wheel blasted I bought from you and will be painting them this weekend. Zody gasser looks real promising, keep the pics coming mate.

Dave

There ought to be an update on 'Look what we have cut out' coming by the end of the week.
Work starts Wednesday moring in Abbey Wood... :-)

[rootesix66]

would that be u at the secret cafe then?

[cabby]

Steve, did u get anything sorted re-bring the gasser over?

[1960Zody]

Hi Tony,
In one of those thinbgs that happen when you least expect them to a guy who lives in the flats opposite the garage came out on Wednesday for a chat about the car and I said "Can we plug a welder into your electric".
So not only do we have electricity, but also never ending cups of tea.
Jon has done a fantastic job with the welder, Sure he'll put the pictures up soon, but if you're coming over to the Breakfast meet next weeks you're welcome to come take a look.

[cabby]

Hi Tony,
In one of those thinbgs that happen when you least expect them to a guy who lives in the flats opposite the garage came out on Wednesday for a chat about the car and I said "Can we plug a welder into your electric".
So not only do we have electricity, but also never ending cups of tea.
Jon has done a fantastic job with the welder, Sure he'll put the pictures up soon, but if you're coming over to the Breakfast meet next weeks you're welcome to come take a look.


Ok m8, as long as your sorted thats the main thing

[Jonny69]

Update!

As mentioned Steve has managed to befriend one of the neighbours and swapped 5 screwed up fivers for the seemingly indefinite loan of one of his plug sockets. This means we have power to weld onsite and can run the non-battery power tools. Thanks to everyone who has offered space, tools and help though - true hotrodders spirit!

http://www.dropfiles.net//files/319/garage/IMG_3710.JPG

Rear quarters. We'll come back to the sills later, I was interested in demolishing more of Steve's car before we do anything constructive. We knew they were a little rusty and Steve had some panels on order from X-Pressed. I've done the rear quarters on my Anglia and I warned Steve in advance that the back of them will need rebuilding as well. A couple of thumps to see how bad it was for comedy photo moments and this chunk of filler fell out:

http://www.dropfiles.net//files/319/garage/IMG_3712.JPG

And the front corner also just fell off with no cutting:

http://www.dropfiles.net//files/319/garage/IMG_3713.JPG

http://www.dropfiles.net//files/319/garage/IMG_3714.JPG

The new panels are superb and a great fit:

http://www.dropfiles.net//files/319/garage/IMG_3715.JPG

I marked a first line along the top of the new panel where to cut and decided it would be an easier repair if I didn't use the whole panel. I cut about 3" off the top of it, marked a new line and made my cut:

http://www.dropfiles.net//files/319/garage/IMG_3716.JPG

As you can see the panel behind is just as rotten, the bottom lip is completely gone so needs to be rebuilt before the new bit can go on:

http://www.dropfiles.net//files/319/garage/IMG_3717.JPG

http://www.dropfiles.net//files/319/garage/IMG_3718.JPG

The rear panel is also rotted in that corner and the end needs repairing. I've been asked how I make panels with few tools and it's quite simple so I'll go into more detail here.

Start by making a paper or card template. If the car has been repaired and you've got to cut the old repairs out first, like we do here, then make the panel to suit what you're going to be putting back on:

http://www.dropfiles.net//files/319/garage/IMG_3719.JPG

Transfer your template to steel, in this case 1.2mm mild steel sheet:

http://www.dropfiles.net//files/319/garage/IMG_3720.JPG

Forming a 90 degree fold for the lip at the top is quite simple but since it's wider than my vice you have to bend it over in a few stages to stop the part getting distorted. Start by bending one end partway, slide it to the other end in the vice and repeat, then fold it over all the way:

http://www.dropfiles.net//files/319/garage/IMG_3721.JPG

The bend will be quite rounded and needs to be sharpened up, which you do by hammering it lightly on the jaws of the vice or workmate with a small hammer:

http://www.dropfiles.net//files/319/garage/IMG_3722.JPG

Then pull a curve into it to match the original back panel. Do this in stages and offer it into position so you get a nice smooth curve:

http://www.dropfiles.net//files/319/garage/IMG_3723.JPG

There's another fold for the bottom lip and forming this is the same as above:

http://www.dropfiles.net//files/319/garage/IMG_3724.JPG

http://www.dropfiles.net//files/319/garage/IMG_3725.JPG

This time the hammering needs a little more skill. Clamp the part in the vice, hold the top of the part and hit the bottom of the curve along the jaw of the vice. You're aiming to flatten the curve so it's a sharp bend:

http://www.dropfiles.net//files/319/garage/IMG_3726.JPG

When you're happy with the shape it's ready to fit later:

http://www.dropfiles.net//files/319/garage/IMG_3727.JPG

Back to the rear quarter repair, I don't know what the original panel looked like underneath, so I've built it up with fresh steel to match the back of the new outer panel:

http://www.dropfiles.net//files/319/garage/IMG_3728.JPG

Close up it looks like this, with a lip running round the bottom. Just tack weld bits like this in place before you final weld them, then you can move them around easily:

http://www.dropfiles.net//files/319/garage/IMG_3729.JPG

Once final welded the outer panel can go on. Start by really cleaning the old steel up with a knot wheel on the grinder, then a few small tacks to hold it on so you're happy with the position:

http://www.dropfiles.net//files/319/garage/IMG_3730.JPG

Then it's a matter of filling in the gaps with more tacks...

http://www.dropfiles.net//files/319/garage/IMG_3731.JPG

...and more tacks until you have a continuous weld all the way across:

http://www.dropfiles.net//files/319/garage/IMG_3733.JPG

Now all it needs is a light grind and a lick of filler:

http://www.dropfiles.net//files/319/garage/IMG_3732.JPG

Don't be tempted to run a long weld because the panel will distort like hell. I've chosen to slightly overlap the panels to make the welding a bit easier as butting the two bits together is trickier and tends to distort more.

On the other side the boot floor is rotten through as well, from a previous repair patch, so that has been cut out completely and started to repair. Inside:

http://www.dropfiles.net//files/319/garage/IMG_3734.JPG

From underneath:

http://www.dropfiles.net//files/319/garage/IMG_3735.JPG

And outside. You can just make out the line I've marked where I will be attaching the new inner panel, same as round the other side:

http://www.dropfiles.net//files/319/garage/IMG_3736.JPG

Here's why it needs cutting back again :D:

http://www.dropfiles.net//files/319/garage/IMG_3737.JPG

Next update I'll finish those repairs off, finish the sill/floor work and it should be good to temporarily slap a bit of paint over for the MOT.

[1960Zody]

And I painted the floor and got the rear lights done... :-)

Might make ut to Watford Rods.
If not, it'll be Old Warden

[1960Zody]

would that be u at the secret cafe then?
Yup, that was us...
See you there...