Return to the road of a forgotten about 5.

[Jonny5]

So i've picked up a new 5.
A 1991 H reg Tungy, 79k genuine miles and has FSH with only eight owners from new.
Car is a really good runner and has a massive pile of receipts that came with it, including the original order form and a sales invoice for £10.5k!
The body is in need of some TLC after languishing forgotten about in a garden for five years but should be able to be sorted to a good standard with minimal parts needing respraying.
Mechanically it needs a general tidy up and some welding in the usual 5 places to get it road worthy, but she should be back out boosting in six months.
I will update on here the progress as i go along.
I'll leave you with a picture below from when we picked it up.

[Jonny5]

With the car having been stood for so long the clutch is stuck to the flywheel, so the first job was to remove the engine.
I stripped down the engine in the bay and got it ready for removal, engine was then loose on its mounts with just driveshafts and the gear selector to unbolt.
I ordered a Valeo green box clutch and dug out a lightened and balanced flywheel from my spares.
Whilst removing the stub axles to move driveshafts out the way i also found it is sitting on full Koni adjustables.

[Jonny5]

Out she comes....

[Jonny5]

Engine was then out and ready to be split to have the flywheel fitted and clutch changed.
Found a brand new set of genuine samcos in the boot too
Few patches of rott on both headlamp panels so have a full front slam panel including both headlamp panels coming.

[Jonny5]

Started to remove the scabby front upper panel to gain access to the worst of the rott.
The engine bay areas where they usually go are all really clean so happy there.
I was massively let down by carpanels4u on the front panel so i had to re order from midland lamps and panels which added time to the welding.
Sills are good with minimal scabbing on inners and only one small hole on each side at the same point.

[Jonny5]

Front panel finally arrived

[Jonny5]

Rott removed..





Welding started.

[Jonny5]

Front panel and welding for front end completed.



Sourced a rott free scuttle panel to replace the one on car that has rusted out really badly.

[Matt Cole]

Excellent start matey. I have both them jobs to do although I might go the fab and patch route.

[Matty]

Looking good. What are the plans? Return back to OE?

[B18ftMOJO5]

Looking good you sure dont hang about when theres work to be done looking forward to this project thread if your last one is anything to go by.

[LiamR]

Love reading this sort of stuff. Gives me back some much needed enthusiasm and inspiration.

Keep it up

[J$£5GTT]

GOOD WORK!

Dont ignore those sections at the rear where the torsion bar fixing bolts go through,all that box section front to back is worth blasting some quality anti rust into like Dinitrol.

[Trevhib]

New Jonny thread

Great start. Looks like you have a stainless crossover pipe included

Did you sell your old car, who took it on?

[Jonny5]

Looking good. What are the plans? Return back to OE?

O.E +, just clean and tidy without getting carried away again.

New Jonny thread

Great start. Looks like you have a stainless crossover pipe included

Did you sell your old car, who took it on?

Cheers Trev, car had lots of goodies included.
The downpipe is a 2.5" stainless one with an enlarged elbow attached to a roller bearing T28

No not sold other car, we now have two

[Trevhib]

Greedy! Glad to hear you still have the original.

[Mr Raider]

Great work.

[LiamR]

Welcome to the exclusive ' I own two tungy 5 gt turbos' club!

Although yours look in better condition than mine!

[Jeff Ninebar]

good to see another save underway

My top tip for doing the windscreen scuttle panel, measure the gap from the lip of the screen recess top to bottom of the windscreen before removing the old one, its very easy to weld in the new panel a few mm out and the gap be not quite big enough to fit the screen and the outer trim rubber seal.

not speaking from experience or anything

[JonnyGee]

Sorry to hijack but where did you get your first car painted and rough price?
Cheers

[Jonny5]

Bit of an update.

The windscreen has been removed and the dashboard is now out ready for welding in the replacement scuttle panel. A massive thank you to Jonathan Smith for doing this for me while i was busy at work.
All the old scuttle has now been removed, but it still needs the underlying metal prepping before the new piece can be welded in. No more horror stories other that the rust we already knew about and all the inner panels are solid
A small repair has also been made to the corner of the front bumper.

More soon...

[Mr Raider]

Good work, are you replacing heater matrix with a new one whilst its all out mate?

[Jonny5]

Good work, are you replacing heater matrix with a new one whilst its all out mate?

Yes mate, will change the rheostat too while im there.

[Thundercat]

Good project and in good hands, just wish I'd been doing it!

[LiamR]

Looking good. Always love seeing project threads as good as this.

[Jonny5]

Sourced some used, but good condition bumper strips for a good price.
The fronts were missing from the car when purchased, but luckily the back one was intact.

[Jonny5]

Update.

New scuttle is now welded in, things progressing nicely.
All welds and bodywork will be refined at a later stage.

[Matt Cole]

You make that look so easy! I can't be arsed taking the dash out!

[Wallace]

[Jonny5]

Small update nothing major...but every step is one step closer.

[jockr5gt]

that,s some very good fabricating and welding nice to see another 5 being saved first class all-round look forward to watching it evolve

[Mr Raider]

Nice work fella, small step however another closer to saving it.

[Matt Cole]

Looks smooth! What make of primer have you used? You going for a spray can or gun?

[Woznaldo]

That's some fantastic work. I love seeing these bodywork repairs, something I've never really tried.

[LiamR]

As above. I want to get an old 5 and practice with the welder so I feel more confident working on the gt turbo.

Great resto thread as ever!

[Jonny5]

Good work, are you replacing heater matrix with a new one whilst its all out mate?

Latest purchase.

[Jonny5]

Looks smooth! What make of primer have you used? You going for a spray can or gun?

Its been taken back to bare metal and then rattle can zinc primed.
All the rattle can painting happening now is purely to protect any bare metal and recent areas of work from flash rust before we get it painted professionally next year.

[Mr Raider]

Good work fella, well worth changing heater matrix whilst dash is out.

[Thundercat]

Check fit heater matrix into housing before fitting seal around it, i've found new ones clash with casing and some trimming is needed to allow matrix to fit fully home.

[Jonny5]

Small Update.

The front end is now finished welding wise.
I'll paint the engine bay when the weathers warmer next year.
Jacked the car up today so we can move on to the passenger sill, initial inspection shows a bit of work needed but nothing massive.

[Trevhib]

Awesome work.

I can't imagine just how much confidence you have with this stuff off the back of the last resto. It must be like, "yeah, I've seen this all before, I know what to do, no problem."

[Wallace]

Awesome work.

I can't imagine just how much confidence you have with this stuff off the back of the last resto. It must be like, "yeah, I've seen this all before, I know what to do, no problem."

I've been thnking exactly the same myself.............you'll piss it Jonny

Cracking work and coming along quite quickly