Yep, our 'solid' Trav turned out to have a nice solid layer of underseal hiding some rather nasty holes. It didn't help that we used a screwdriver first, then moved on to trying a needle scaler which is great for stripping off hardened old underseal - and for finding rust holes.
Doctor JLH continued his examination of the patient and declared the floor 'terminal'. Most of it has to be replaced. About 6-8 years ago it had been patched (by a 'professional') who had simply plated over the top of the old rust holes and given it a good coat of unserseal to hide the evidence. The six inch wide strip of new steel down each side of the car turned out to be simple cosmetic make-up, with the real wrinkly skin still lurking underneath it all.
Since I was last there (a month ago, mid-November), JLH have completely stripped the entire car. Apart from easy things like the front guards and bonnet, all doors, windows and interior trim has been removed. Even the rear section including the roof and all of the wood has been removed as one piece. This allows Jonathon much easier access to the rusted rear wheel arches, and "since the car is now just a shell, why not do a proper job and shotblast the entire car, top to bottom". Why not indeed?!
Our original plan of an engine swap and brake/suspension upgrade has become a complete rebuild. The only thing left untouched will be the seats and the wood, both of which were excellent to begin with.
So, the latest specs are :
MG-F 1.8i engine.
Ford Capri 2.8 V6 gearbox.
Front anti-roll bar.
Coil-over adjustable gas telescopic shocks on the front
Upright adjustable gas telescopics on the rear.
Ford Sierra vented front disc brakes.
Ford Escort MkII axle with 3.9 ratio.
Ford Escort rear disc brakes with Mazda 323 calipers.
14" steel wheels with Minor hubcaps and chrome rings.
Rust-free body and chassis rebuild.
Complete respray inside and out.
0-130MPH speedo unit.
80mm diameter tacho and 50mm water temperatue and oil pressure gauges fitted into a driver's side glovebox cover.
New headlining and carpets.
Immediate tasks :
Sandblast the chassis and body panels.
Etch prime chassis and body panels
Repair cracks and rust holes in front doors
Begin fitment of engine and gearbox
