Monaro Underseal/Fettle project

[marko14a]

For anyone that may be interested here is a brief write up on the work I am doing on my Monaro.

Bit of background, the car was parked up back in April and declared SORN. I bought a Clio as a runaround and as something for the Mrs to learn to drive in.

The Monaro sat on the drive, I washed it occasionaly, and warmed it up every now and again but other than that it just collected dust.

I decided as it was going to be there for a long time I would underseal it, as they are well known for having little underbody protection, understandable being from Oz, and I am paranoid about rust after owning an S14a, a Hilux and 2 fords! :D

I will also be doing a few other repairs/mods while I'm at it.

Pre pictures disclaimer(s) - I am not doing this for the underside to look good, just to protect it! Also some of my methods, especially for lifting the car, are not the best. Don't copy! :wack: Also my picture quality is generally crap!

Anyhooo, here's a few before pics:

http://i11.photobucket.com/albums/a159/mk6mark/Photo017_001.jpg
http://i11.photobucket.com/albums/a159/mk6mark/IMAG0225.jpg
http://i11.photobucket.com/albums/a159/mk6mark/IMAG0226.jpg
http://i11.photobucket.com/albums/a159/mk6mark/IMAG0227.jpg

As you can see, other than bits that are bolted on, the actual chassis isn't in bad nick. So I set about taking bits off like a madman :eek: :D

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/263698_10150264151178970_592528969_7753869_1480216 _n.jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284243_10150278702318970_592528969_7893216_4277913 _n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/267242_10150285842588970_592528969_7972642_3876855 _n.jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/184086_10150285884498970_592528969_7973258_4380390 _n.jpg

I should add at this point, I am doing the car in sections, i.e. strip, clean, protect, rebuild back end then reposition car and start on the middle/front sections.

The underside was then blasted with a pressure washer, and I set about with the wire wheels removing any loose surface rust (hardly any to be honest) and keying up the painted surface. This is not a bare metal refurb. I don't have the patience!

http://i11.photobucket.com/albums/a159/mk6mark/IMAG0312.jpg
http://i11.photobucket.com/albums/a159/mk6mark/IMAG0313.jpg
http://i11.photobucket.com/albums/a159/mk6mark/IMAG0314.jpg
http://i11.photobucket.com/albums/a159/mk6mark/IMAG0315.jpg
http://i11.photobucket.com/albums/a159/mk6mark/IMAG0316.jpg

I then went over the underside again with a solvent wipe and started applying the zinc primer I erm aqcuired from work! Markos top tip - use the nastiest colour primer you can find, that way you won't miss any spots when you apply the top coats!

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/314904_10150349423283970_592528969_8455355_1955276 610_n.jpg
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/294298_10150349423433970_592528969_8455358_1758564 19_n.jpg

Once that had dried and got in my hair, onto the first top coat.

Epoxy mastic 121 if anyone is interested.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc7/302970_10150356808823970_592528969_8494216_1004790 360_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/299601_10150356809083970_592528969_8494218_2141851 834_n.jpg
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/302077_10150356809128970_592528969_8494219_2683736 59_n.jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/318325_10150368398653970_592528969_8556796_1563973 227_n.jpg

That's where I'm at for now, as I have run out of epoxy :wack:

In between coats I will be filling as many gaps as I can with seam sealer.

Once the second coat is on, I am going to primer and epoxy the subframe and arms and will start rebuilding the back end. Then I will be applying Dynax UB on the underside and injecting Dynax S50 into the sills and other box sections.

If you stuck it this long, thanks. There will be more to come.

Mark

[ferretca18]

if only more people did this then cars would last soooooo much longer! Good job!

[marko14a]

if only more people did this then cars would last soooooo much longer! Good job!

Thanks! There's only 60 of this model and 800 or so Monaros in total in the country. I though I should try and make it last!

[markcro]

Nice job! Fair play.

[R3k1355]

Good stuff man no rust issues for that car :thumbs:

You planning on fitting some polybushes to the subframe while it's out, or fit a thicker ARB?

[marko14a]

I'm unsure to be honest. I don't want to end up with a car that vibrates again, and I want to keep it reasonably standard with it being quite rare. It does wallow like mad though and feel pretty vague!

They are cheap too, £100 for the bushes, and you can get a 'road response pack' that sharpens up the steering for about £200.

[Guy]

Good work, nice to see someone looking after their car with a bit of TLC :)

[marko14a]

Minor update, I was bored and poor so spent the last couple of hours doing this:


Subframe de-bushed and primered:

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/297864_10150377653718970_592528969_8607041_1390661 107_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/312036_10150377654073970_592528969_8607046_3302487 18_n.jpg

Also, fuel tank straps and prop given a quick spray. Can't see it lasting long but it will look nice the first time I rebuild it!

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/302406_10150377654323970_780905286_n.jpg

[marko14a]

Yay more goodies!

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/308225_10150382435083970_592528969_8634574_1431468 741_n.jpg

More progress coming up this weekend.

[gonzomagic]

What's the difference between mastic and generic under seal?

[marko14a]

You mean like Waxoyl, the Dynax, that sort of thing?

[gonzomagic]

You mean like Waxoyl, the Dynax, that sort of thing?

Yeah. Even 3M underseal.

[alanjuggler]

epoxy mastic isn't an underseal, it's an epoxy 2 pack paint that can then be undersealed :nod:

you can pick it up from www.rust.co.uk

[marko14a]

The way I understand it, which may be totally wrong is the epoxy is essentially just a tough paint. The Bilt Hamber stuff is slightly different in that it contains zinc phosphate like the primer I used, so should be more 'active'

It does the same job as the 3M, waxoyl etc though, simply providing a barrier against the elements. (Albeit without dripping all over the driveway!)

I'm putting the wax (Dynax UB) on top as a 'belt and braces' measure. That is the typical rubberised coating, which dries touch dry.

[marko14a]

Got quite a bit done this weekend, yesterday went round with the seam sealer:

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/391371_10150386119853970_592528969_8657564_1805201 056_n.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/383796_10150386120013970_592528969_8657566_2255475 15_n.jpg

Today, injected the sills with the Dynax S50:

Before:

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/308395_10150386120118970_592528969_8657568_1968011 073_n.jpg

During/after:

Atomised by the injection lance:
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/388211_10150386120793970_592528969_8657575_1453042 423_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/303266_10150386120523970_592528969_8657572_1759668 209_n.jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/317653_10150386120633970_592528969_8657574_9601121 31_n.jpg

Bungs replaced and sealed over:

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/293567_10150386130433970_592528969_8657642_323652_ n.jpg

Also did the other bits of chassis and box section I could get to.

Second coat of epoxy applied, and half the subframe painted. The Bilt Hamber stuff is a bit glossier than the other stuff, but seems to cover better.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/307702_10150386179888970_592528969_8658065_1228565 573_n.jpg
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/382849_10150386177308970_592528969_8657994_2147409 109_n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/308747_10150386177303970_592528969_8657993_1174171 727_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/293559_10150386177218970_592528969_8657991_3380650 47_n.jpg

I didn't mix quite enough paint so still have half of one wheel arch to finish, the subframe and suspension arms to finish, then that's it for epoxy. Onto the wax coat!

[marko14a]

More progress this weekend.

First, I have covered most of the epoxy (excluding what is under the bumper) with Dynax UB underbody wax. One 750ml can of spray covered a substantial section of the main underside. I then applied a few coats with a foam brush in the wheel arches, as these take some hammer, and went over the underside again, as it spreads really well.

It dries to a lovely matt finish too, not picked up in the pictures:

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/377652_10150395474808970_592528969_8722686_9512686 72_n.jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/314586_10150395474978970_592528969_8722691_1797682 349_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/308227_10150395475223970_592528969_8722692_7217572 64_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/378444_10150395475528970_592528969_8722696_1197218 779_n.jpg

Once that was dry, the fuel tank, heat shields, carbon canister and the fat arse were bolted back on:

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/299834_10150395476793970_592528969_8722707_8659777 48_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/378708_10150395476893970_592528969_8722708_5434815 36_n.jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/300842_10150395476628970_592528969_8722705_2344386 60_n.jpg

The subframe was given it's first coat of wax:

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/312232_10150395476288970_592528969_8722702_1743463 016_n.jpg

And now I'm at a stop until I get some subframe bushes.

So, I tarted up some other bits:

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/377972_10150395476178970_592528969_8722701_1199136 123_n.jpg

Man points lost here as most of that was done with Hammerite :wack:

And finally for today, using the worst 'paint' in the world (spray Hammerite):

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/373988_10150395476408970_592528969_8722703_8102611 40_n.jpg

[gonzomagic]

Looks good buddy.

[skinz180189]

Spray Hammerite, what a PITA. Might as well just piss on them.

[marko14a]

Thanks!

[marko14a]

Spray Hammerite, what a PITA. Might as well just piss on them.

:nod: It has a similar consistency to food colouring in water! :wack:

[marko14a]

Well, it's going to be a couple of months before I can buy the subframe bushes so I decide to put the car back together today with the old ones for now. I got it from a rear end with just the tank on to road worthy again in about 5-6 hours. Now I feel like I have been hit by a bus! It's not easy on your own.

I only managed a couple of pics as most of the time I had something heavy balanced on my vegetables. Then it got too dark to take pics. I shall get some more next weekend.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/378668_10150434801848970_592528969_8866566_2039625 760_n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/389563_10150434802078970_592528969_8866569_8831307 17_n.jpg

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/388795_10150434802558970_592528969_8866573_1886354 460_n.jpg

[DeanS15]

Nice work mate :) watching with interest :)

[marko14a]

Thanks :)

[marko14a]

More pics from last weeks work:

(Excuse the half painted diff!)


http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/374293_10150446670658970_592528969_8900525_7488272 26_n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/383755_10150446670478970_592528969_8900524_3335322 47_n.jpg
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/377111_10150446670218970_592528969_8900523_1480238 408_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/378756_10150446669958970_592528969_8900522_9956018 94_n.jpg
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/381024_10150446669718970_592528969_8900521_3526938 43_n.jpg

I also rewired the rubbish stereo so there was an aux feed in the centre console:

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/380074_10150446669468970_592528969_8900519_7024647 56_n.jpg

Finally, a quick wash as it was looking sorry for itself after all these months:

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/384988_10150446671303970_592528969_8900528_1979654 153_n.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/388196_10150446671063970_592528969_8900526_8106792 10_n.jpg

There's still a bit to do touching up etc but essentially the rear end is done once the new bushes are in. I have decided I will give it another coat of spray wax and tidy up the shoddy looking bolts once the car has been aligned properly.

[marko14a]

Well, lack of daylight and money has meant I haven't done a great deal on the car recently.

Today I got the bumper off and got the front end up in the air. Wings are to come off and gearbox while it's in this position.

I should be able to get a large area of the car done now, then drop it back down and strip the suspension off.

Here it is looking sorry for itself:

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/390082_10150499064188970_592528969_9091329_1670265 56_n.jpg

Sideline job #46 - mount power steering cooler properly. Not with cable ties :D

[stevieBoy]

Hi I like what your doing to the **.
The wifes got same as yours also in red. out of interest how much rust did you find underneath. Shes been wintering hers for the last 3 years but we did have to change both power steering pipes because of rust so you got me thinking about tackling the big Aussie with underseal. What bushes are you going for, arnt you happy with the handling?
Cheers Ste
ps Will post a piccy of ours

[marko14a]

A bit more:

Wings off! I have decided as these don't see any direct hammer from the elements, and there is currently no rust, I will just give them a couple of coats of wax.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/385778_10150537829873970_592528969_9244114_1888798 185_n.jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/401728_10150537829998970_592528969_9244116_1871694 277_n.jpg

I have also decided to get the car road legal again by April. Must crack on! Lots to do!

[marko14a]

Wings waxed today:

(With an excessive amount of Dynax!)

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/402394_10150592254598970_592528969_9417043_6443434 06_n.jpg?dl=1

I was going to take off the gearbox today, but, well nah!

[stevieBoy]

Tis customery to reply to a reasonable question.:indiff:

[Deacon]

Tis customery to reply to a reasonable question.:indiff:


76648

[marko14a]

Tis customery to reply to a reasonable question.:indiff:

Sorry, never even noticed that post!
If Deacon hadn't bumped the thread I probably never would have!

With regards to rust underneath, I have barely found any on the actual chassis/body itself. Just surface rust on arms, subframe etc. Now I am getting round to the front I am starting to find a bit more but nothing major.

I also had to change the power steering pipes and cooler for the one you can see in th epics above. (Which I still have to mount properly!)

Bushes, I think I am going for Energy Suspension subframe and diff bushes; http://www.energysuspensionparts.com/proddetail.asp?prod=3%2E4125 and the road response pack from Monkfish for the front end; http://www.monkfishperformance.co.uk/2004vxrmonaroframeset.html

The handling is OK as it is, just sometimes seems a bit vauge, so hopefully they will sharpen it up without compromising ride quality.

[marko14a]

A bit more done, inner wings Dynax'd:

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/421671_10150611370853970_592528969_9468873_1172934 25_n.jpg

The wings and lights are back on, and the gearbox is hanging off. Although I'm struggling with that now.

[Petrol]

Good job this :thumbs: Should last a lot longer :)

[marko14a]

Thanks Petrol :thumbs:

I must admit to failing/bottling out. I haven't managed to get the gearbox off and underseal the full transmission tunnel. The car has to be back on the road by the 31st and I have to:

Apply 2 coats of epoxy to currently primered areas.
Apply dynax to above areas.
Bleeed the brakes.
Bleed the clutch.
Change the gearbox oil.
Change the diff oil.
Fit the propshaft.
Fit the exhaust.
Change the engine oil and filter.
Connect the handbrake.
Re-fit heatshields.
Mount power steering cooler.
Re-fit front bumper.
Re-fit side skirts.
Re-fit arch liners.
And some other stuff :wack:

Basically 2/3 of the car will be fully undersealed and the rest wont have been touched. I now plan to do the remaining areas of the car over the coming weekends in small sections. E.g one wheel arch one weekend.

[marko14a]

One week to MOT day and the Monaro is in one piece, serviced and ready to go!

I'll try and get some pictures when it is up on the ramps.