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Thread: Project Black.

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    Mark 4's Avatar

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    Project Black.

    So the time has finally arrived.

    I have facilities, money and some spare time to start the rebuild.

    Gonna need some help on here though as this is a lot more than I have ever taken on before.

    The plan is to strip down to bare chassis, modify the bulkhead so that bigger tubs can be fitted and get it acid dipped and seam welded.

    All of the running gear will be standard but beefed up where possible.

    Then I need a forged engine, tubs etc.

    Who is around to help me on here and possibly at the odd garage meet sometime in the future ?


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    I'm considering something very similar! Not sure if I'll end up acid dipping the shell - I have heard a couple of horror stories of the acid remaining and dripping out *years* later and ruining stuff... I do have easy access to sand blasting, however...!

    Please be sure to document what you're doing!

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  4. #4
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    Hay Garry, maybe we could synchronize and solve problems together

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    This is sounding like a real labour of love. Good luck
    '97 Manual Legnum in silver with some subtle mods

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    Ultimately this is the only way to cure the inherent rust problems once and for all. Have you thought about heavy duty galvanisation once itís acid dipped?

    Where acid dipping or hot-dip galvanising is concerned, if thereís the means to rotate the bare dipped shell a few times across three axes after itís out the bath that should stop any acid collection problems. Easier said than done mind.. any plans to do the same for body panels, or splitting the rear arch seam joints to ensure complete acid dip coverage?

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    the temperature required for hot dip galvanising could warp the shell so you'd need to have some references to measure the body afterwards. You'd also need to re-tap every thread and then add further corrosion resistance making for a very long job.

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    Mark 4's Avatar

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    Thanks guys. This is exactly the kind of input I am looking for.

    As said - this is far beyond anything i have done before so knowing about potential pitfalls is really useful.

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    Quote Originally Posted by Mark 4 View Post
    Hay Garry, maybe we could synchronize and solve problems together
    Sounds good! I'm going to be documenting everything and this is my next project on my YouTube channel, so feel free to ask any questions!

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    I'm also going to be following with interest - following my major restore/protect in 2012 mine is now probably worse than it was 9 years ago. That is still better than most are, but I do need to be thinking about heavy duty work again!


    It will be great to see you making a return too, Mark.

  11. #11
    Mark 4's Avatar

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    Thanks Nick, I am sure that I will be wanting your input.

    What do you think of my outline plan ?

  12. #12
    Nick Mann's Avatar

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    It sounds like a great plan! I have zero knowledge or experience of acid dipping. It sounds professional though!!

  13. #13
    Mark 4's Avatar

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    It's what Gowf recommended. Blasting does a good job but it does not get rid of all the mastic that is hidden in the lapped joints. That can be an issue when it comes to welding.

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    Ah. Good to know. Are you familiar with the procedure? So for example at the strut tops where there is a triple layer of metal, how do you make sure the acid has not only done it's job, but also comes back out again? I'm under the impression that trapped acid would be detrimental to keeping the car rust free!

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    Mark 4's Avatar

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    No Nick, it is all alien to me but I do know that I am not going anywhere near the acid tank.

    I am going to seek advice from the guys that do it.

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