Lotus Sunbeam Restoration
Project Undertaken March 2011 and completed March 2012.
Dave's Sunbeam has already had an extensive stripdown, metalwork and been semi-prepped for paint. We will be taking it through to completion.
The first thing to address is some rather untidy previous repairs. The Lotus tunnel mods are very messy (this was originally a Talbot shell) although solid enough, so the sealer is cleaned back, some pin-holes welded up and then all the previous welding properly dressed back before re-applying fresh sealant.
The other main area of concern is the nearside edge of the scuttle. This is showing some bubbling on the surface and looks to be an untidy repair from underneath, so the area is cleaned back for inspection. Sure enough, there is an area of corrosion that has been fillered over as well as a rather poor metal repair. These will be fully cut out and new repair sections let in.
The suspect area of scuttle is cut away, and new metal let in, and the area lead filled. A small section of sill is has also been overlooked during the previous metalwork session, so this is cut out and repaired. The underside is then steam-cleaned and coated with Gravitex Stonechip compound.
With the metalwork and underside out of the way, the shell is subject to a thorough ripple assessment, and smoothed out accordingly, before being rubbed down and masked up for a good coat of high-build primer.
With the primer on, a 'guide coat' is applied to assist in getting a perfectly flat finish during the block-sanding stage that will follow.
Moving on to the panels, one of the doors needs a lower re-skin. The lower section of the original skin is cut out, and the replacement trimmed to size, joggled and clamped in position before being plug-welded in and lead-filled.
The inside and frames of the doors are blasted, and these, along with the bonnet are smoothed and then given a heavy coat of 'Reface' spray filler, which will help us achieve a super-flat finish during the block-sanding process.
Next the shell is wet-flatted before the underside areas are masked, and it is moved into the booth ready for paint. It is then painted inside and out, initially with Standox base coat, and then with Max Meyer 2K Clear Lacquer. The colour is the original Moonstone Blue.
Next step is to begin detailing parts and reassembly work. First we gather a batch of parts together for Satin Black paint. These are blasted if metal or thoroughly cleaned and 'keyed' up if plastic, smoothed, primed and painted in 2K Satin Black. At this stage the front bumper, all bumper end caps, headlamp trims, grille, tailgate hinges & rear window trims are done. Also the front bumper irons are blasted ready for a coat of super-tough Polyeurathane paint along with the headlamp back plates which have been blasted and had some sheared-off bolts replaced.
A replacement headlining has been sourced and fitted as the ones supplied were tatty. The 'A' and 'C' pillars have been trimmed in black vinyl to match, and the windscreen and rear windows fitted (as well as the freshly painted trims which sit behind them). Also at this stage the wiring loom has been cleaned and installed along with the dash, instruments, steering column, pedal box and various other parts. (steering wheel is in for cosmetic effect, but it does need repainting!)
Next we blast a large batch of components (suspension parts etc) and paint them all with a super-tough polyeurathene two-part coating. We can then proceed with reassembling the car!
At this stage we also fit and align the doors. of the various doors we had to choose from we still did not have a complete set of hinges, but suprisingly managed to source a brand new one from a Peugeot dealership!
Carrying on with some of the detailing and trim work, firstly the rear bumper which was damaged... we fabricated new mounting plates and spot welded them in place before repainting. The rear bumper irons were also damaged, so new ones were made from scratch. Also at this stage, we have another batch of parts cleaned up and ready for satin black paint..... door handles, rear window trim etc etc.
Meanwhile we have sourced some Original Equipment 'Marchal' spot lights which are also being refurbished ready for fitment. We are also installing some modern 'creature comforts' at Dave's request. Alarm, modern stereo, central locking and electric windows are all to be fitted.
You may have noticed we have been missing a critical part - the engine!! Well this has been over at John Toovey's shop being rebuilt, and I must admit he's done a great job! 186 bhp on the dyno, so should be lively enough.
We collect the engine, bolt it up to the gearbox, exhaust manifold and engine mounts and get it in there!
Meanwhile we get the tyres on the wheels, and continue to source replacments some of the missing/damaged parts..... The radiator is re-cored, and a NOS fuel sender tracked down.
Next follows the remainder of the reassembly work, and then some painfully long waits while rare missing parts are made (front coiliover conversion, rear shock absorbers) and sourced (indicator lenses, parcel chelf etc). Also a series of road-tests and relevant tweaks and alterations are carried out until we are happy the car drives as good as it looks!
