420GSI tourer mini restoration

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N1tr0_9
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Re: 420GSI tourer mini restoration

#16 Post by N1tr0_9 » Sun Sep 13, 2020 10:16 am

Fitted the coolant temp sensor for fans to the rad.

Video of above.

https://www.youtube.com/watch?v=otqEV0-3OkM

N1tr0_9
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Posts: 61
Joined: Thu Jan 25, 2018 10:28 pm

Re: 420GSI tourer mini restoration

#17 Post by N1tr0_9 » Sun Sep 13, 2020 10:17 am

Made serious progress today. I spent ages prepping the slam panel. I de-rusted the underside, painted it in Hydrate 80, then bonda zinc primer, then etch primer. Left it on the radiator to dry.

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Re: 420GSI tourer mini restoration

#18 Post by N1tr0_9 » Sun Sep 13, 2020 10:19 am

Then painted the underside in metallic green. Only doing the underside as all the top will be done properly by the bodyshop. The underside will be difficult to get to once it is welded in, hence me doing it now. I also did the rear side of the bonnent latch stiffener and the front bumper mounts.

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N1tr0_9
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Re: 420GSI tourer mini restoration

#19 Post by N1tr0_9 » Sun Sep 13, 2020 11:33 am

Then i welded the slam panel to the car. I have very little shielding gas left, so i had to avoid the blustery winds!

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N1tr0_9
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Re: 420GSI tourer mini restoration

#20 Post by N1tr0_9 » Sun Sep 13, 2020 1:21 pm

Ground all the welds back and then gave it a dusting of etch primer to give it at least a little protection.

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Also painted the inner edge of the nearside front wing, as it had been rubbed down to bare metal but not actually painted.

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crepello
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Location: Herts

Re: 420GSI tourer mini restoration

#21 Post by crepello » Sun Sep 13, 2020 3:34 pm

Quite an encouraging story, this. A welcome contrast to the usual stories (on FaceBook especially) of decent cars being taken on the opposite trajectory.

Did you basically drill out the existing spot welds and then plug weld at those locations on reassembly?

Cthomas
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Location: Kent

Re: 420GSI tourer mini restoration

#22 Post by Cthomas » Sun Sep 13, 2020 4:47 pm

N1tr0_9 wrote:
Sun Sep 13, 2020 9:21 am
Cthomas wrote:
Sat Sep 12, 2020 11:11 pm
Nice to see you here James. I’ve watched the sd1 police car on Matt’s YouTube
Yes that was a result. He also did a road test of this car.
Was talking to Matt this morning about both drive tests.
He collected strut tops for the Alfa 145.
When are you getting back on the diesel sd1? Looking forward to seeing the manifold bits you got from me.
Are you still keeping the 420gsi?
I would love a 420gsi saloon again but a rover 216 vdp sd3 came up like I had in the 90’s
Rover 216 vdp 1990
Old ones
Rover 216 vdp 1986 my dads last car
Rover 420 gsi 1992 miss this one
Rover 214 sei 1995
Rover 820
Rover 3500 vp sdi
Rover 2600 sdi

N1tr0_9
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Re: 420GSI tourer mini restoration

#23 Post by N1tr0_9 » Sun Sep 13, 2020 5:44 pm

crepello wrote:
Sun Sep 13, 2020 3:34 pm
Quite an encouraging story, this. A welcome contrast to the usual stories (on FaceBook especially) of decent cars being taken on the opposite trajectory.

Did you basically drill out the existing spot welds and then plug weld at those locations on reassembly?
Yes drilled out the existing spot welds on the donor panel, the used a paint scraper and hammer to cut through to the final parts. Then plug welded back through this same holes. I did loads of videos showing the process. I’ll post a link. James

N1tr0_9
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Re: 420GSI tourer mini restoration

#24 Post by N1tr0_9 » Sun Sep 13, 2020 5:45 pm

Cthomas wrote:
Sun Sep 13, 2020 4:47 pm
N1tr0_9 wrote:
Sun Sep 13, 2020 9:21 am
Cthomas wrote:
Sat Sep 12, 2020 11:11 pm
Nice to see you here James. I’ve watched the sd1 police car on Matt’s YouTube
Yes that was a result. He also did a road test of this car.
Was talking to Matt this morning about both drive tests.
He collected strut tops for the Alfa 145.
When are you getting back on the diesel sd1? Looking forward to seeing the manifold bits you got from me.
Are you still keeping the 420gsi?
I would love a 420gsi saloon again but a rover 216 vdp sd3 came up like I had in the 90’s
Small world. Not sure if I’m gonna use the manifold bits. There has been so much interest in that one I think I might just keep it all original.

Yes got to sell the 420gsi. I only took it on as I didn’t want to see it get broken up.

N1tr0_9
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Re: 420GSI tourer mini restoration

#25 Post by N1tr0_9 » Sun Sep 13, 2020 5:47 pm

@jimspolicev8sd1 wrote:Picked up a genuine GSI bonnet with bulge for £60. Looks rough as a badger, because its been painted grey with badly shaken rattle cans, but it is completely rust free.

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N1tr0_9
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Re: 420GSI tourer mini restoration

#26 Post by N1tr0_9 » Sun Sep 13, 2020 5:48 pm

Fitted the coolant pipes

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N1tr0_9
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Re: 420GSI tourer mini restoration

#27 Post by N1tr0_9 » Sun Sep 13, 2020 6:38 pm

Spent an age prepping, degreasing, etch primering and then spraying green on parts of the slam panel. Ive just concentrated on the bits that will be hidden under the wings or generally a pain to get to. Hopefully the bodyshop will make it all look super pretty later.

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https://www.youtube.com/watch?v=EbXfVFp0Eyo

N1tr0_9
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Re: 420GSI tourer mini restoration

#28 Post by N1tr0_9 » Sun Sep 13, 2020 6:39 pm

Simon the previous owner provided me with a GSI spec front bumper which I'm chuffed with. It has the cut outs for front fog lights. This car never had them, but they look cool and easy enough to retrofit.

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I took another look at the offside front wing, and the crusty bit. I made the decision that if I was gonna have the bonnet and bumper painted, I should also sort the rust. I was thinking about buying a wing, but when I unbolted this one its super solid at the bottom, just one nasty bit of grot. So I hacked it out and used a section out of a scrap wing from the bubble 200 to repair it. Welded it in and then bonda primer.

Rust out and new section trimmed.

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Welded in and ground back

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Primer

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Then I refitted the rad and fan so its pretty much ready to be started up and taken to the body shop.

Rad in

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Front bumper balanced on

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N1tr0_9
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Re: 420GSI tourer mini restoration

#29 Post by N1tr0_9 » Sun Sep 13, 2020 6:40 pm

Exciting news, car is now at the excellent Midland Performance and Retro to be painted. Its a bit of a trek for me, 400 miles round trip, but I know its in very safe hands with Mike and team.

All loaded up

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Obligatory fuel stop photo

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Arrived

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2 days later, Christmas Eve, and Mike is already sending me photos!!!!!! Unbelievable work ethic. Thanks Mike.

Bonnet, wing, bumper, slam panel all being painted, as well as touching in some blemishes to the leading edge of roof and offside rear wing and lower edge of offside rear door.

Cant wait to get it back, hopefully end of Jan.

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N1tr0_9
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Posts: 61
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Re: 420GSI tourer mini restoration

#30 Post by N1tr0_9 » Sun Sep 13, 2020 6:40 pm

Got the 420gsi tourer back from the excellent MPR Midland Performance and Retro. Looks stunning. They painted both front wings, the bonnet, front bumper (including re texturing the black bits), the slam panel, front of roof, offside rear wing and offside rear door lower section. They then polished the whole car so it gleams!

They did a blinding job. Even the underside of the bonnet looks mint. The slam panel looks like its been polished smooth and so you would never know it had been repaired. Love it.

No i just have to put it all back together.

Ive ordered some new bolts for the headlamps and the plastic trims that hold the underbelly panel and arch liners so when they arrive ill get stuck in.

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It was turning heads on the 200 mile journey home.

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At home with the 827 stable mate

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Underbonnet area

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