John's Space - Wolseley Hornet 303JCY - http://www.youtube.com/user/johns199126

Day 1 - Thursday 4^th October 2007

      Took off trim

      Removed all glass

      Removed bonnet, doors and boot

Day 2 - Saturday 6^th October 2007

      Removed rear lights, petrol tank, 1 headlight and 1 side light and engine manifolds

      Brought 1 cylinder of gas, welding wire, nozzles, anti-spatter spray, grinding and cutting/sanding discs

Day 3 - Sunday 7^th October 2007

      Took off wheels

      Started to labelled wiring loom

      Removed starter, dynamo and soaked all of the sub-frame bolts in WD40

Day 4 - Friday 12^th October 2007

      Jacked up car

      Dropped sub-frame and engine onto floor using trolley jack

      Jacked up car further and pulled engine and sub-frame forward

Day 5 - Saturday 13^th October 2007

      Took out the rear sub-frame

Day 6 - Sunday 14^th October 2007

      Stripped rear sub-frame ready for blasting and powder coating

Day 7 - Tuesday 16^th October 2007

      Removed engine from sub-frame

      Removed suspension from front sub-frame

      Straightened bent cross members of both sub-frames

      Both sub-frames are in good conditions

      Masked all threads and bearing surfaces ready for blasting prior to powder coating

Thursday 18^th October 2007

      Took sub-frames to Bownes of Bissell Street for steam cleaning, blasting and powder coating

Day 8 - Saturday 20^th October 2007

      Removed clutch housing from engine, clutch plate and flywheel nut

      Awaiting delivery of special puller to remove fly wheel

      Removed front engine pulley, timing chain cover, crank shaft and crank shaft sprockets complete with timing chain

      Timing chain and tensioner rubbers need to be replaced

      Drained engine oil

Day 9 - Saturday 27^th October 2007

      Split engine and gearbox

      Removed crank shaft con-rods and pistons

      Bores and pistons are good but rings need replacing

      Slight wear on big ends, main bearings good

Day 10 - Sunday 28^th October 2007

      Removed break drums from back plates

      Skimmed drums in lathe

      Cleaned engine and gearbox

      Stripped cylinder head

Day 11 - Sunday 4^th November 2007

      Removed and labelled wiring loom from engine bay

      Took out brake master cylinder

      Loosened clutch master cylinder

Day 12 - Tuesday 6^th November 2007

      Collected cylinder head from Stirchley (refaced)

      Removed speedometer

      Labelled up more wiring loom

      Fitted jig to front of car

Friday 9^th November

      Re-faced exhaust valves seats. Ground in 8 valves

      Brought head gasket set and engine bearings

Day 13 - Saturday 10^th November 2007

      Refitted valves and springs to cylinder head

      Completely removed front wiring loom

      Cut off front wings

      Removed left hand front shock absorber

Day 14 - Sunday 11^th November 2007

      Fitted new rings to pistons and new engine bearings

      Assembled pistons in block and fitted crankshaft

      Fitted cam shaft

      Prepared front of car for welding repairs

      Removed front side indicator assemblies

      Ground off remains of old front wings and prepared surfaces for welding

Day 15 - Tuesday 20^th November 2007

      Removed steering column, rack and pinion

      Cut out rusted metal from back of front wheel arches

Day 16 - Thursday 22^nd November 2007

      Trimmed back edges of front panels ready for welding on new wings which are on order

Day 17 - Tuesday 27^th November 2007

      Removed back bumper

      Repaired inner wing arch on drivers side

Day 18 - Thursday 29^th November 2007

      Mounted car on ‘swing jig’

Day 19 - Friday 30^th November 2007

      Removed drivers shock absorber bracket and repaired end of bulkhead cross member

      Repaired shock absorber bracket which was very corroded

      New panels arrived

      Treated inner wing arch with phosphoric acid in treat rust

Day 20 - Monday 3^rd December 2007

      Refitted drivers side shock absorber bracket

      Sprayed inner wing arch with hammerite

      Repaired top of bulkhead

Day 21 - Tuesday 4^th December 2007

      Removed head lining

      Continued welding bulkhead

Day 22 - Tuesday 11^th December 2007

      Removed drivers side A panel

      Cut out drivers side step panel

      Cut out corroded metal from door pillar

Day 23 - Wednesday 12^th December 2007

      Trial fitting of new A panel

      Make up repair strips for door pillar and welded into place

      Brought new step panels

Day 24 - Saturday 15^th December 2007

      Hang driver’s door to correctly fit A panel.

      Weld panels into place

      Sand off bottom of drivers door and treat with phosphoric acid

      Repair and paint scultel top panel

      Start to repair edge of corroded front panel

Day 25 - Sunday 16^th December 2007

      Removed drivers door

      Cut off drivers side step panel and bottom of rear body panel

      Trimmed flange on floor panel prior to welding (step panel)

Day 26 - Tuesday 18^th December 2007

      Started welding drivers side floor cross member (corroded in sill)

      De-rusted interior of sill

      Began fitting drivers side step panel

      Rust treated inner wheel arch (drivers side)

Day 27 - Saturday 22^nd December 2007

      Finished welding drivers side step panel

      Repaired body panel behind drivers side rear glovebox

Day 28 - Monday 14^th January 2008

      Started to Repair top edge of front panel – drivers side

Day 29 - Tuesday 15^th January 2008

      Finished repairing front panel – drivers side

      Test fitted front wing on drivers side – slight adjustment needed prior to welding the front wing onto the car

Day 30 - Friday 18^th January 2008

      Cut off nearside ‘A’ panels

      Cut out all rusted metal from inner wing area

      Rust proofed all welded work on offside of car

      Welded in patch on shock absorber bracket.

Day 31 - Monday 21^st January 2008

      De-rusted engine bay

      Began repairing nearside wheel arch

      Cut off nearside sill top and cleaned out

      Began repairing near side inner sill brace

Day 32 - Tuesday 22^nd January 2008

      Painted engine bay with undercoat

      Treated nearside inner wheel arch with phosphoric acid

      Painted offside front panel with Hammerite

      Started welding nearside inner wheel arch

      Fitted nearside top shock absorber bracket

Day 33 - Saturday 26^th January 2008

      Continued to weld inner wheel arch on near side

      Finished welding near side inner sill brace

Day 34 - Sunday 27^th January 2008

      Repaired front end of nearside sill (welded new metal)

      Finished welding nearside inner wheel arch

      Repaired nearside top scuttle panel by welding new metal in

      Trial fitted nearside front wing – slight adjustment needed

Day 35 - Tuesday 29^th January 2008

      Finished welding nearside inner wheel arch

      Fitted nearside A panels

      Cut new nearside sill top to fit in 2 new parts

      Trial fitted nearside front wing – slight adjustment needed

Day 36 - Thursday 31^st January 2008

      Welded nearside top sill panel

      Welded new metal into base of radiator cowl

      Painted nearside inner wing arch and engine bay with primer

Day 37 - Friday 1^st February 2008

      Repaired top of nearside front panel

      Welded 2^nd half of nearside top sill

      Reinforced engine steady bracket with fillets

Day 38 - Sunday 3^rd February 2008

      Painted inner wheel arches and engine bay in primer

      Repaired metal around gear lever hole

Day 39 - Monday 4^th February 2008

      Repaired front edge of door frame on drivers side

      Joined offside floor edge at front to inner wheel arch and painted with primer

Day 40 - Tuesday 5^th February 2008

      Fitted both front wings and started to weld into place

Day 41 - Wednesday 6^th February 2008

      Finished welding nearside front wing

Day 42 - Friday 8^th February 2008

      Started to cut away back panel under boot

      Removed supports for boot floor to expose corrosion

Day 43 - Saturday 16^th February 2008

      Supported car under the rear wheel arch so the rear body jig could be removed

      Cut off rest of back panel

Day 44 – Monday 18^th February 2008

      Blended off-side ‘A’ panel into sill step

      Cut out corroded metal from offside of boot bottom

      Blended in rear side panel into off-side sill panel

Day 45 – Tuesday 19^th February 2008

      Repaired off-side rear body panel at bottom

      Rebuilt corroded metal under off-side rear bumper

      Began repairing boot floor

o       WELDER BROKE DOWN

Friday 22^nd February 2008

      Collected welders from repairers – dry joints in printed circuit board

Day 46 – Sunday 24^th February 2008

      Continued repairing boot floor (cut out corroded metal and welded in new)

Day 47 – Monday 25^th February 2008

      Welded rear end of off-side wheel arch

      Started repairing near-side boot floor (cut out corroded metal and welded in new)

Day 48 – Tuesday 26^th February 2008

      Finished welding near-side boot floor and wheel arch

      Wire brushed complete rear-end prior to fitting new rear panel

      New rear panel adjusted to fit body

      Fitted off-side end to rear panel and welded to wheel arch

Day 49 – Friday 29^th February 2008

      Fitted near-side end to rear panel and welded to wheel arch

      Drilled holes in rear-end of body to spot weld rear panel onto it

      Refitted rear jig in preparation for tilting the car 90˚ to de-rust and paint underside of car

Day 50 – Sunday 2nd March 2008

      Tilted car 90˚ on jig to start working on the underside on Monday

Day 51 – Monday 3^rd March 2008

      Wire brushed nearside sill and floor area

      Treated with phosphoric acid

      Cut out corroded metal in rear nearside quarter panel

      Spot welded new metal to bottom and rear of nearside quarter panel

      Primed treated areas with hammerite

Day 52 – Tuesday 4^th march 2008

      Wire brushed nearside rear wheel arch

      Repaired rear shock absorber mounting

      Finished welding repair patches to nearside of boot floor

      Treated wheel arch with phosphoric acid

      Sprayed wheel arch with primer

Day 53 – Thursday 6^th March 2008

      Tilted car opposite way (offside up)

      Repaired shock absorber mounting

      Wire brushed floor and sill

      Cut out and repaired corroded metal

Day 54 – Monday 10^th March 2008

      Welded nearside front wind to front panel

      Wire brushed, de rusted and primed off-side rear wheel arch

      First coat of primer put on under floor area

Day 55 – Tuesday 11^th March 2008

      Repaired battery carrier, and offside rear seat panel

      Wire brushed and acid treated panel area under rear bumper

      Wire brushed and vacuumed out boot floor prior to acid treatment

      Acid treated boot floor

Day 56 – Thursday 13^th March 2008

      Wire brushed offside sill and under floor area

      Acid treated and repaired pin holes and sprayed with primer

Day 57 – Friday 14^th March 2008

      Sealed all welds on offside with seam sealer

      Repaired edge of front panel and joined to off-side of front wing

Day 58 – Monday 24^th March 2008

      Sprayed underside of car in red primer

      Seam sealed nearside

      Applied red primer to areas not previously sprayed

Day 59 – Tuesday 25^th March 2008

      Applied filler to repaired areas

      Sprayed underside with ‘stone-chip’

Day 60 – Thursday 27^th March 2008

      Painted boot floor with ‘chassis black

      Sprayed ‘chassis black’ on inside of the front wings and front panel

Day 61 – Wednesday 2^nd April 2008

      Applied second coat of ‘stone-chip’ to underside of car

      Started to reassemble rear subframe

Day 62 – Friday 4^th April 2008

      Pressed in new bushes to both radius arms

      Reamed plain bush in each arm to fit mounting spindle.

Day 63 – Monday 7^th April 2008

      Cleaned and painted rear suspension units and fitted to the rear sub-frame

      Fitted sub-frame Assembly to the car after treating sub-frame with “Di-nitrol”

      Fitted flexible brake hoses and rear shock absorber to nearside

Day 64 – Tuesday 8^th April 2008

      Fitted offside rear shock absorber and restored back plates

      Fitted hydraulic cylinders to back plates and brake shoes to the offside

      Sprayed steering rack in primer

Day 65 – Wednesday 9^th April 2008

      Made up and fitted copper brake pipe to rear brakes

Day 66 – Thursday 10^th April 2008

      Fitted steering rack

      Took gearbox to home workshop to dismantle

      Starting painting engine block

Day 67 – Friday 11^th April 2008

      Started to dismantle gearbox

      Took of differential unit and outer main shaft bearing

Thursday 17^th April 2008

      Collected riley elf cylinder head from being resurfaced (restored hornet cylinder head fitted to my Mum’s 69 Elf as this was distorted from overheating)

Day 68 – Friday 18^th April 2008

      Still working in home workshop

      Ground in valves

      Refitted Elf cylinder head to Hornet engine

      Finished painting engine block and cylinder head in white primer / orange undercoat / BMC engine green overcoat

 Day 69 – Saturday 19^th April 2008

      Finished stripping gearbox (centre main shaft bearing in very poor state)

      Pressure cleaned gearbox housing and bell housing

      Masked off gearbox housing and bell housing and painted

      Mounted rear brake drum in Lathe ready for skimming

Day 70 – Monday 21^st April 2008

      Cleaned and checked inside of gearbox

      Cleaned and inspected main-shaft and lay-shaft

      Sourced new gearbox bearings and differential bearings

Day 71 – Tuesday 22^nd April 2008

      Dismantled main-shaft and inspected synchro-mesh cones – ok

Day 72 – Friday 25^th April 2008

      Applied first coat of paint to engine bay – BMC TARTAN RED

      Also painted offside sill

      Trial fitting of off-side rear brake drum. All drums require skimming

      Car inspected by paint sprayer to get quote

Day 73 – Sunday 27^th April 2008

      Skimmed all 4 brake drums removing approximately 10 thou. from each

      Made up new spindles for handbrake cable attachment to rear radius arms

Day 74 – Monday 28^th April 2008

      Applied 2^nd coat of red to engine bay. Problem with reaction to previous coat

      Flatted down with 120 and 240 paper prior to applying barrier coat

Day 75 – Tuesday 29^th April 2008

      Sprayed top coat to boot – same problem as with engine bay

      Flatted down ready for barrier coat

      Experimented with aerosol lacquer – not successful

Thursday 30^th April 2008

      Picked up gearbox bearings from supplier

Day 76 – Thursday 1^st May 2008

      Sprayed engine bay and boot space with barrier paint to prevent reaction with top coat

Day 77 – Friday 2^nd May 2008

      Applied top coat to engine bay and boot space (this will be lightly flatted prior to spraying with clear lacquer)

      Carried on rebuilding gearbox with new bearings

      Fitted main-shaft, followed by lay shaft

      Checked gear engagement before fitting pinion. All gears engaged except neutral.

Day 78 – Saturday 3^rd May 2008

      Unable to get neutral because of sticking synchro-cones. Lubricated generously and all well

      Fitted pinion, selector gate and gear change rod

      Fitted new carrier bearings to differential unit and fitted to gearbox with new gaskets

      Adjusted crown wheel/pinion mesh with shims to give correct engagement backlash

Day 79 – Tuesday 6^th May 2008

      Transported engine from workshop to Wolseley’s garage

      Loaded engine onto small trolley for ease of moving around

Day 80 – Friday 9^th May 2008

      Fitted engine to sub-frame with new mountings

Day 81 – Saturday 10^th May 2008

      Fitted new brake cable quadrants to rear radius arms with new pins

      Fitted split pins to drive shaft couplings after torquing up

      Fitted suspension and drive shafts to engine and sub-frame

Day 82 – Monday 12^th May 2008

      Fitted radiator fan and fan belt

Day 83 – Tuesday 13^th May 2008

      Fitted radiator and hoses

      Painted bulkhead with final coat of stone-chip and sprayed with di-nitrol.

Day 84 – Thursday 15^th May 2008

o   PROBLEM – How do you fit the engine without a hoist?

o   ANSWER  -Fit the car to the engine

      Put engine and sub-frame onto trolley

      Pushed engine and sub-frame assembly under car using the trolley

      Carefully lowered the car using 2 trolley jacks over engine and sub-frame

Day 85 – Friday 16^th May 2008

      Fitted rear wheels and supported car on ramps

      Removed rear body jig

      Supported front of floor on tyres and removed front jig

      Carefully jacked the sub-frame the last 2” and aligned bolt holes – alignment perfect despite much welding

      Fitted front off-side shock absorber and radius arm bracing arms with new rubbers

Day 86 – Thursday 22^nd May 2008

      Painted solenoid, mounting plate and distributor mounting

      Made up leather gasket to fit underneath brake and clutch master cylinders

      Removed masking paper from wings

Day 87 – Friday 23^rd May 2008

      Fitted new brake master cylinder and old clutch cylinder

      Fitted pressure valve to rear brake pipes

      Fitted new clutch slave cylinder

      Began making new front copper brake pipes

      Temporally fitted front wheels to support car

Day 88 – Tuesday 27^th May 2008

      Fitted new front brake pipes and off-side front brake shoes

      Fitted exhaust with new mounts and clamps

Day 89 – Wednesday 28^th May 2008

      Fitted nearside brake shoes.

      Made up gasket and fitted distributor carrier

      Fitted solenoid and bracket.

Day 90 – Tuesday 3^rd June 2008

      Fitted nearside front shock absorber

      Attached cables to handbrake

      Drilled out body trim clips

      Cleaned interior of car and rubbed down prior to painting

      Applied seam sealer to front bumper mountings, and to previous internal welds

      Started to mask up ready for interior spraying

      Painted bottom of front panel with tannic and rust treatment

Day 91 – Wednesday 4^th June 2008

      Finished masking ready for interior spraying

      Sprayed isolator to front and rear interior

      Sprayed stone-chip to bottom of front panel

Day 92 – Thursday 5^th June 2008

      Blew out and vacuumed interior

      Dry sanded isolator

      Sprayed interior in beige undercoat (2-pack)

   Sprayed interior with TARTAN RED – 90% complete

Day 93 – Friday 6^th June 2008

      Removed front grille from bonnet

      Removed chrome trim from doors

      These items to be taken to platers to re-chrome stripping, polishing and re-plating.

Monday 9^th June 2008

      Removed tyres from wheels (local tyre service)

      Took them for shot blasting and powder coating

      Took chrome work to platers for chrome stripping prior to polishing

Tuesday 10^th June 2008

      Collected wheels from blasters

Day 94 – Wednesday 11^th June 2008

      Stripped paint from bonnet back to bare metal

      Cleaned and repaired water channels under the door windows with fibreglass resin (heavily Corroded)

      Treated bonnet with tanic acid prior to painting.

Day 95 – Thursday 12^th June 2008

      Removed defective filler from off-side rear panel

      Bled brake system

      Fitted new tyres to wheels and then fitted them to car

Day 96 – Friday 13^th June 2008

      Continued to repair door water channels

      Welded repair patch to front edge of bonnet

      Small welding repairs to door channels

Day 97 – Monday 16^th June 2008

      Final resin repair to door channels

      Surplus resin used on boot floor to seal any porous welds

      Repaired corrosion in door bottoms after de-rusting and treating with tanic acid.

      Sprayed bonnet in primer

Day 98 – Tuesday 17^th June 2008

      Fitted engine stay with new brushes

      Rubbed down doors

      Rubbed down primer on bonnet

Day 99 – Thursday 19^th June 2008

      Dismantled starter

      Fitted new brushes and Bendix spring

      Cleaned, treated and painted starter in top coat

      Began fitting new wiring loom

Day 100 – Friday 20^th June 2008

      Fitted regulator box and fuse box, starter motor, flasher unit and speedometer

Day 101 – Friday 27^th June 2008

      Fitted clutch hydraulics

Day 102 – Saturday 28^th June 2008

      Cleaned an treated heater unit

      Bled clutch

      Fitted battery for circuit testing

      Fitted HT cable from battery to starter