May While Stephen has been battling with persistent illness, progress
has not been as fast as we would like. Nevertheless work continues.
I’ve overcome my ‘fear’ of power tools and pressed on with
completing the remaining woodwork for the backend.
Little 'off ' here
After gathering dust for what seems like an eternity the
replacement boot door framework has been cut, shaped and fitted with
the outer skins of the doors being sanded back ready for a coat of
primer. The curved window pan woodwork has also been made and
After a trip to the timber merchants for yet more
Ash, all the woodwork for the boot area framework has been cut and
shaped using what was left of the originals as a pattern. Stephen
has repaired the badly corroded boot sill support rail and a new
piece of ‘Z’ section steel has been purchased which forms the
lateral support for the boot floor.
welding z rail into position
With all the components assembled ready for fitting
an early morning start was made with the goal of having the main
framework at the rear end in place by teatime. Using the many
reference photos taken at the time of dismantling (and a good deal
of logical thinking!) we set to and by late afternoon were satisfied
with a good days’ work as all the new parts had been installed.
Z Rail and other metal supports in
Does it fit? Almost!
This will be followed by final preparation of the steel framework
behind the rear axle which supports the boot wall, the fitting of
the side boot wall panels, boot floor support rails and remaining
outer skin panels - all of which have been previously made and
stored away pending fitting. Once these jobs have been undertaken
the new rear seat box can finally be fixed into place along with the
The rear fibre-glass moulding requires some final
repairs and sanding then this too can be fitted along with the boot
Stephen has repaired the replacement front grill panel retrieved
from Suffolk – this will probably be one of the last items to be
refitted once CDK has been repainted.
Overall a decent step forward after many months of staring at the
big void out t’ back!.
May 24 & 25th
Carrying on where we left off last week all our efforts at the
moment are centred on completing the rebuild of the rear end. First
job was to weld in the 3 rails which support the boot floor.
While the paint was drying the final fitting of the new
rear set box was undertaken.
A previous test fitting confirmed a perfect fit and it didn’t take
long before another section of the great void had been filled in.
With the box in place the rear shelf was next to go in followed by
the batten which supports the seat back.
Once this was done attention turned to the preparation of
the rest of the metal boot framework ready for a good coat of rust
proofing primer. After an hour or so of work with wire brushes,
chipping hammer and mop disk in the grinder the satisfying task of
Before finishing on Sunday the paintbrushes were out
again – the primed metalwork receiving a top coat of
resin based sealing paint.
Next weekend should see the fitting of the replacement boot walls
and, after offering the rear moulding up yet again, we will be able
to mark where the boot door hinges need to go. It will be very
satisfying to see the boot doors back in place and final
confirmation that all that new wood and metalwork has gone back in
the right place – quite an achievement considering how decayed the
original was. Aren’t jigsaws great!