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]

The car is now rolling again, all the suspension parts will be painted when it gets stripped back down. Front end bolted together a lot easier than the rear apart from the top wishbone ball joint, how do you get it done up? whatever I did it just spun, I didn't want to fit the new ones as its coming apart again before final build

Sump is a little low but tyres had gone flat (think they need resealing on the rims) so will raise a little more

[Pete Clayton]

Hi Paul, I did check a little while back but have forgotten think it was 3-4 inches. I'm going to put the axle and front suspension back on next so will see! The plan is to start building it back up to check i'm happy with everything before stripping back down and painting the chassis

[Paul Sheridan]

Looking good Pete, how close to the ground is your sump?

[Pete Clayton]

It does still fit on the bracket but needs to be angled up a lot more than it was originally designed too, would have to fashion a new tensioner. I might get one of the little Suzuki alternators so its not as tight.

[Big Vern]

Pete, Can you still mount the alternator?

[Pete Clayton]

Bit of a mile stone for me today, engine is now supporting itself :)

I went down the unit this morning and cut all the relevant plates and bits of box section and then this afternoon Lloyd joined me and welded them up. Feel like i'm making some progress now.

and the otherside

You may wonder why its offset, this is why

[Pete Clayton]

Had a spare hour this evening so drilled the gearbox mount and dropped the engine and box back in. Only thing I am now concerned about is how close i've managed to get the new rail to where the prop will fit in the gearbox

These are the plates i've made for the engine mounts

[Pete Clayton]

Finally done a bit on the car today after not touching it for a couple of months. Wanted to try and get the gearbox mount sorted.

This is how I had left it

Angle iron clamped in place and tack welded

And finally all welded in place, just need to tidy up the welds (wire feed was playing up). Cheers to my mate Lloyd for doing the welding.

[Pete Clayton]

Spent a bit of time down the unit with Lloyd today.

Started by cutting off the original gearbox mounts and a section out of the rail

Fitted the needle bearing to the crank, new flywheel, clutch and then bolted the gearbox up and fitted starter

Offered it all up and bolted the box mount in place. Need to put in a new rail to get the strength back and do a bit of bracing and make up the engine mounts. Need to get some gas for the welder

Then we moved on to Lloyds projects. Got the TSR 1.9 engine out of his missus mk2 Golf. Has a 2.0 16v lump going in

Then he decided to start cutting up the donor car to give us some more space

[Pete Clayton]

Went down the unit for a little while this afternoon. Cut the original engine mounts off, put the bulkhead loosely back in place and offered the engine back up. Crank pulley is a bit close to the front rail and turbo and thermostat outlet a bit close to the bulkhead hmmm bit of thinking required. I now have a gearbox now as well. Going to buy some box section and plate and some engine mount rubbers and fabrication can begin.