Phaeton project

[Pete Clayton]

Went and picked up a Phaeton from Big Vern (Cheers mate!) as a rebuild project. Its an S1 but has some S2 bits from the looks of it like the rear bodywork which has the bulges for spring hangers.

The plan is to strip it back to the bare chassis and then build it up from there, new bushes, calipers etc and a new engine just not sure what yet! It came with some goodies such as some Revolution wheels with yokos, a nice stainless exhaust and a new hood.

Looking forward to getting stuck in. Here's some pics, excuse the quality they're from my phone

[Pete Clayton]

Got the car stripped back to a bare frame again today ready to be welded up and painted. A harness bar will be added later in the build.

Comparison of the chassis when I started and now

Before (had started looking at the gearbox mount hence section missing)

Now

[Pete Clayton]

Got the axle back in today, made up the panhard rod bracket and dropped the car on to its wheel. The panhard rod bits are only tacked in place at the minute and the vertical needs some triangulation.

Made up a scuttle support as well

Just the lower intercooler bracket to make now and then the chassis can be stripped bare for final welding and painting :-)

[Paul Sheridan]

Great result. Can't find many people these days that can do something for you and then be happy with a fiver !!

[Pete Clayton]

Last night cleaned everything up again, tacked the bracket back in place then whipped the axle out. This morning I popped to an old school welders opposite a site I was visiting. The chap had a quick look and said i'll do it now, you bring it in and i'll set up the bench. 10 minutes later job done :) he did both sides and one of the trailing arm brackets. I asked what I owed and he said a fiver and if I need anything else doing to come back, I gave him a tenner and set off very happy.

[Pete Clayton]

Thanks for the comments guys. The plan is to clean everything up again with the grinder and then tack it in place, the axle will then be removed and given to my mates dad who used to be a welder to do it with his Arc. As the shock mount is load bearing I want it to be 100%

[Paul Sheridan]

Just to make this topic clear from a safety point of view, as this and other threads may well be read by people who do not do a great deal of welding. If a weld does not penetrate correctly, grind it out, clean it up and start again, NEVER weld over the top of a bad weld, as all you are likely to do is penetrate into the weld and not the good metal.   

[Dave Adams]

I know that fed up stage.....stick with it its worth it in the end.

[Dave Adams]

Gassless welders “flux“ the joint as they weld and often get good penetration. too good sometimes they blow holes too easily.

[Pete Clayton]

Feeling a bit disillusioned with the car tonight. Went down to see if I could make the bracket for the panhard rod and broke the shock mount on the n/s again. I think i'm going to just tack it in place and then take the axle out and take it somewhere to be welded. The welds are just not penetrating and its not lack of power, melted the tip on the welder oops! Just want the chassis welded up and finished so I can reassemble, fed up!

[Pete Clayton]

Wasn't happy with the bracket I made up for the n/s so made it up again

Ready for welding off the car

Tacked in place and solid, after a couple of failed attempts whacked the power right up and its going no where now

A bit of triangulation to the n/s shock mount ready for a bracket for the panhard rod

Started mounting the panhard rod, the vertical piece needs some triangulation and I still have the other mount to make but you get the idea

Very pleased with how its coming together