FOM The Clubman Estate

[Tupers]

I've bought a set of MK3 Cosmic wheels that should be with me on Wednesday.

They've been blasted and are in raw aluminium at them moment but this is what they'll look like when painted.

 

[Robotstar5]

Looking good got any ideas where the top tailgate will be sourced from?

 

[Angusdog]

Nice wheels - I particularly like the pseudo knock-off center caps.

 

[bod]

Happy birthday! Hope you had a good one; you're lucky to have such a nice family with a good taste in presents!
Keep up the great work,
Matt

 

[Tupers]

Looking good got any ideas where the top tailgate will be sourced from?

I think I'm going to have a go at making the top myself out of polycarbonate. I like to have it done in glass but I''m too scared to get a quote.

Nice wheels - I particularly like the pseudo knock-off center caps.

Thanks Angus I thought they looked pretty different. The knock off looking bit is actually a polished part of the wheel but I haven't decided if I'm going to have mine like that or paint those sections black.

Happy birthday! Hope you had a good one; you're lucky to have such a nice family with a good taste in presents!
Keep up the great work,
Matt

Thanks Matt, they're well in tune with what I need. Got to figure out what I want to tap them up for at Christmas now.


I started a bit late today but got straight onto cutting the original skin lip off each side of the tailgate.

Once that was all cleaned up I folded two 90 degree sections that would become the new skin lips.

After running them trough the shrinker and a lot of trimming I had two of these.

A bit of Celco action to make use they fit properly and then it was on to welding.

They still need a little finishing on the outside but soon you wont be able to tell it's not an original part.

I also got some shinny stainless steel front subframe and door shims for the final build.

 

[Tupers]

My new wheels turned up this morning. One needs a bit of repair work and one needs a new insert but for the price I paid I can'y complain.

I think the face depth of these is really cool.

 

[brightspark]

you have your work cut out there who blasted them . looks like they have laced em no problem with a good key for the build up primer

 

[Tupers]

you have your work cut out there who blasted them . looks like they have laced em no problem with a good key for the build up primer

The previous owner had them blasted honest.


I spent ages getting the centre that was cut out of the tailgate lined up and then tacked in last night.

And even more time welding it up as there was a 4MM gap all the way around, I hate thick cutting discs.

I did a little linishing on the ends of the frame and flicked some zinc over them.

Should look good when it's got glass up top.

 

[Robotstar5]

I suppose a powered glass like the Freelander would be too difficult?

 

[Tupers]

I suppose a powered glass like the Freelander would be too difficult?

I've bought a Freelander tailgate to do surgery on but as far as my time table goes I can't do it.

 

[Tupers]

After much deliberation about how to lock the tailgate I've decided to go with a simple squeeze lock that will retract two pins from the door frame. Nice and simple and it'll barely cost me anything to build.

I started out by cutting a hole for the pinch tabs in the centre tailgate.

Then I drilled a hole in each side for the door frame for the pin to go into.

Last week a I cut a couple of thick steel squares and drill a 10MM hole in each to give the pin a little more support at each end. I've also spotted some little nylon top hats and the hardware store that I might insert into them.

The top of the frame was in dire need of strengthening so I made a top cap from 1.5MM steel and welded it on. This was unbelievably hard to bend but it's stiffened the frame up brilliantly.

 

[Angusdog]

Could you not use the original arrangement from the doors? Or a lever as per the attached pic - can you tell I'm a photoshop expert

Still, looking fab. The upper door will be interesting to watch come together. I imagine like the rest of your build, it's going to look like how BL should have done it from the start (even though I love the rear doors on ours).

 

[zx9]

Might be worth have a look at an early 2dr Range Rover for ideas on the tailgate latch. The panels on Rangie tailgates rot quite badly so you should be able to pick up the internals for next to nothing.

 

[Spot the welders dog]

Lov'ing your work

Maybe using two of these may assist with the door latch: comes sprung loaded so will close secure when required without having to operate the handle.

This is what it looks like >

pic taken from here

May even be able to incorperate a MK1 boot handle to keep 'the look'

PS: the wheels look very nice - a friend has justed fitted some 1100 specials cut down as split-rims - very nice too!

Keep the updates coming...

 

[Tupers]

I did think about making a latch system like that but for now I'm keeping it simple.


I took a trip to the shops and found some nice 8MM i.d nylon stepped washers to use as bushes for the locking pins.

The holes in the tailgate and door frame needed drilling out to 11MM and then the stepped washers slotted right in.

I also picked up some 8MM mild steel rod to use for the pins.

After much chopping and welding I got one side 99% of the way there.

The mechanism still needs a bit of tweaking but it's working the way I wanted.

 

[Angusdog]

Nice stuff. Any idea on latching the upper window to the tailgate?

 

[Tupers]

Nice stuff. Any idea on latching the upper window to the tailgate?

Oddly that'll use a rotating latch like the one to illistarated earlier, I just need to find an old truckman cab that I can steal one from.


Progress on the estate has really ground to a halt recently as I've been busy on customer projects but I'm hoping to whittle out a little more time to get this rolling again.

I have at least been buying shinny things to keep me happy starting with a set of Dunlop DJ93 tyres at about 35% off.

I also got a nice steering wheel that's currently on it's way to me from Portugal, kudos if you can guess what it's from.

Today was one of those aforementioned days when I managed to whittle out a little time to get something done that should have been finished ages ago.
When I pulled the old boot floor out the old mounts for the rear seat also went. I'd made the new captive plates to remount the seat ages ago but didn't get around to fitting them until this afternoon. I also tock the opportunity to move the seat base up at the front and rear to make it easier to hinge and fit carpet underneath.

 

[oz.]

I also got a nice steering wheel that's currently on it's way to me from Portugal, kudos if you can guess what it's from.

The 'Abarth' stamped into it gives it away as being from a fast Fiat. 600 or a 131?

 

[400-ascona]

Definately 131?

 

[Tupers]

It's from an Autobianchi Abarth A112.