The story so far. We took one innocent and un-abused Suzuki SJ413 away from the farm it had retired to 11 years ago with the sole intention of taking it apart and discarding all the pretty bits to enable us to rebody the chassis into something more interesting, namely a replica of a 1930’s open top sports car. This is day 2 and aside from a few wires, cables and bolts the task is all but done.
The first job of the day was to get the chassis and the body separated. The theory was the six bolts would come undone with little or no persuasion and we would place chocks between the two parts, this worked a treat on the front as both chassis bolts snapped off in the chassis, the other four surrendered a lot easier but there things started to go awry. Despite a fair deal of brutality the body wouldn’t part. The angle grinder was called in to action and despite the removal of the offending bolts, everything stayed put. At this point common sense would dictate that there had to be more bolts somewhere. Unfortunately there was 1/2 a tonne of Buckinghamshire on the underside of the car. After a few minutes I was wearing most of the mud and two more bolts had revealed themselves. With some relief the body finally separated and we were back under way. The remainder of the work passed without hitch, it just seemed never ending. As lunch time arrived we were in a position to take the body to the metal recyclers. The easiest way was to strap the body down to the chassis and take it lock and stock, get them to remove the body with their forklift and return the chassis home and for once everything went as planned.
(If only I had actually taken a picture of the body coming off then we would have something interesting to put here, in absence of something interesting, here are the pictures of the before and after.)
Once home the final job was to remove Buckinghamshire and return the chassis to the garage. We had some fun with the pressure washer and stood back to admire the results.
(The two blue bags in the background contain the swept up mud that was attached to the chassis)
Time was getting on and Connor had a train to catch so we shot round to the garage and then we hit upon the bit I hadn’t really planned properly, or indeed, at all. Getting a now non running SJ back into a seriously uphill garage. Things started out ok, we got it squared up and it was moving pretty freely right up to the pot hole one metre before the door. Try as we might we couldn’t move it further. I tried to use the towball of my car against the chassis, which seemed like a really good idea to me. The fact that Connor didn’t think it was should have warned me of the dangers as Connor rarely thinks. Ten minutes and one dint in the bumper later, the SJ was at the bottom of the slope with my towball hooked under the chassis. After much cursing and a trip home for resources (a lump of 4×4) I was just strapping the wood to the chassis when a nice Polish chap turned up and set about manhandling the car into the garage pretty much single handedly. I couldn’t thank him enough but I am now pretty afraid of getting the car out the garage again.
As the monthly car budget has been spent, there won’t be much work done until after Easter but I do need to rig something up to get over the mountain in front of the garage. I think I will look at rigging up a winch system or for the time-being seeing if the starter motor will stand up to the task. I cetainly won’t be experimenting without reinforcements, just in case it won’t.
After waiting three weeks for the planets to align and the Dalai Lama to pop round and bless the project I found myself unable to delay things any longer. The time had arrived to remove the body from the SJ. First things first, this is occurring on our drive, with no special tools, just large amounts of foolish confidence. The logistical issues started even before the battery was disconnected as my roll cab had to be manhandled from my workshop to the front of the house. This necessitated a ramp to be made and moving most of the workshop around to get the tools out.
At the crack of nine o’clock the first spanner was wielded in anger. The bonnet and the rear door offered no resistance, the same could not be said for the doors. Somebody somewhere in Japan must be pissing themselves at how they designed the door hinges to be held on with large cross head bolts and no amount of persuasion caused them to yield. As the hinges are needed for the rebody the easy option of cutting them off was unavailable to us so the next best option of welding nuts to the bolts was called into action. This required the welder being unearthed from the bowels of my workshop and manhandled up the garden in a wheel barrow replete with punctured tyre. Oh the joy of it all. The joy continued as the welder’s shroud collapsed and the tip melted. This happened to be the last tip and the first road trip began to buy some welding supplies. Eventually all the bolts surrended and the doors parted company with the body.
After that is was merely a case of removing everything that looked like to was attached and didn’t want to be. The wiring loom was removed and carefully marked up. The last time I built a car the wiring proved more complicated than Sudoko after a Tequila tasting session and I was mindful not to suffer a repeat. .
Dinner was enjoyed from the comfort of the SJ’s seats
The afternoon was spent in the same vein as the morning, going through the endless list of parts that needed removing. None of it was particularly taxing, a number of parts really didn’t want to budge but were made to do so, I had to create a puller to remove the steering wheel and it didn’t half go with a crack. A number of the redundant parts were perfectly serviceable and hopefully they will bring a few pennies back into the pot as will weighing in the body at the local metal recycling plant.
I am feeling quite nervous about the next stage, as I am not exactly able bodied and it looks quite heavy. I can’t quite get my head around how it will play out I guess I will have the answer by tomorrow night.
I thought it was time to give an update on how things are progressing. Although I haven’t published much, plenty has been going on behind the scenes and endless photographs of bits of plywood aren’t exactly interesting reading.
So as things stand, the task of cutting out the plywood parts is complete. This involved sticking the full size patterns onto the sheets and cutting around them. This was easy work and all down to the thorough job John Cowperthwaite did in producing them.
(Apologies for the poor photographs in part due to the Severn Trent Van blocking access to my garage preventing me from getting the panels outside)
On Monday, Connor and I drove to Newport Pagnell to collect the donor vehicle for the project. A very reasonably priced Suzuki SJ413. It has spent the last 11 years on a farm being used as a “learn to drive” vehicle for the Farmer’s daughters. It has amassed a whopping 150 miles since 2003. The body gently succumbed to rust over the last decade but mechanically it is a low mileage, unmolested example of the marque. It was happy to start, go into gear and the chassis is pretty much perfect. I don’t think I could have found a better starting point for the Midge.
(pictures courtesy of Connor)
I have just completed the first bit of real construction. The transmission tunnel comprises of 9 pieces of plywood and it went together pretty well but I think I will dry build the other panels onto the chassis before skinning them with aluminium so that I can get the fit just how I want it before committing myself to destroying £150 of aluminium.
(the glued transmission tunnel drying out in the warmth of the hallway allowed by the generosity of @no1LindaMason)
As I want two clear days to take the body off the SJ and I am going to need the help of Connor for the heavy work, this will have to wait until I can commandeer him away from college, however the progress won’t be stalled as I have the powder coating oven to build, at the moment it is cunningly disguised as a filing cabinet and a double oven. Time to get the angle grinder out me thinks
Keep posted by subscribing to my blog for the continuing adventures of me and my Midge (MkII)
Can I just point out powder coating is unnecessary and just something I fancied doing
All to often these days we see You Tube videos of reckless and dangerous driving affecting the lives of cyclists. After my accident I have tried to raise awareness of the need for greater tolerance by all road users to allow us all to get to where we intend to be in a safe manner.
Yesterday I sent an email to a road haulier regarding a you tube video of a reckless pass by a lorry on a cyclist. I received a reply from the company’s Operations Manager and I am impressed by the manner in which he responded. I have copied it out below in full.
I often criticise, so it is only right I praise.
Perhaps there is a chance for us after all.
Thank you for your email regarding the YouTube video.
Fagan & Whalley Ltd take driver training and road safety in general very seriously and have invested much time recently in promoting cycle safety, both from the point of view of the HGV driver and indeed from the view of the cyclists.
As recently as this Monday we provided a HGV and our Training Coordinator to Greater Manchester Police as part of their on-going campaign for education of road safety.
In this instance it would appear the driver has misjudged the oncoming traffic island and had to cut-in sharply, and thankfully a collision was narrowly avoided.
The driver has been reprimanded for his actions and will attend our safety course in the very near future.
Thank you again for contacting us and be rest assured we take these instances very seriously
Midge MkII Build Diary part 1 (of many)
I guess this is part one of the Mighty Midge (MkII) build story. The plans arrived today. As you can see, they are very comprehensive. How it goes, only time will tell.
A fair portion of my monthly budget went on buying the plans from John Cowperthwaite at Lightning Cars and sorting out the security for garage the car will be stored in so it will be a fairly quiet month on the build. As a number of the patterns are simply reversed for each side I bought a sheet of 12mm MDF and I will cut out a templates in that and make any mistakes on the cheaper material. From there I will use a template cutter on my router table to make the identical panels in a fuss free manner.