The container is here ;D ;D ;D

Pics of my Cappo to follow

oooooooooooooooooooohhhhhhhhhhhhh??

Got delivery of the car yesterday, I've been waiting since the first days of October. Bought it through ebay(very VERY cheap though)

Engine is very smokey, bodywork you'll see below. Goodthing is that it hasn't been modified in any way, seals are all good and everything works. So all I have to do is rebuild the engine and sort out the rust.

Spent 1.5 hour last night to take off as much metal as I could before the wife called to go back home

I'm sure you'll get it knocked into shape soon enough.  It certainly needed saving (thumb)

Have you had a look under the dreaded carpet though to get a look at the floor pan?

Hi Mac81,  From what I see , you,ve done a good deal !!!  I hope you don,t have to undo a lot of previous attempts to repair-- with the usual snotty welding attempts --best to find a cappo that,s not been messed with... silver one too !!!  empty fuel tank AND NO CD PLAYER !!!  How many miles on the clock (smokey ? )  Nothing to a man of your calibre -  I,m sure you,ll keep us all posted over the comming months with the resurection  GL !!

Haven't taken the carpets out yet but I don't care ;D

93k miles. It came with a clarion Cassette player. The toolkit is complete, the roof bags are MINT as is the spare tyre.


Months? Car will be done by the end of January and when I say done, I mean FULLY rebuilt engine, not a single spot of rust and the smoothest welds ever and that's a firm statement. 8)

Pics(hundreds of them) to follow  :P

Looks bad to me....You need al youre spare time to renovate this one!!

Are you putting all six new sills on it?

by saying six you mean the two inner and one outer on each side? The old ones are definately going but dunno if I'll replace all of them with original ones or devise new ones on the inside and use only the outer original ones.

These photos should have a warning to viewers of a delicate nature.
I have a copy of the instructions for the original Clarion radio cassette if you want them for authenticity :)

“ Quoted from Mac81, posted Wednesday, December 2nd, 2009, 8:49:54pm at here ” by saying six you mean the two inner and one outer on each side? The old ones are definately going but dunno if I'll replace all of them with original ones or devise new ones on the inside and use only the outer original ones.

Yes that's what mean. Its easier to take the lot off and start again. you ll know what i mean when you get stuck in.

By saying "start again" you mean custom built all of them?

“ Quoted from Mac81, posted Thursday, December 3rd, 2009, 10:17:16am at here ” By saying "start again" you mean custom built all of them?

No buy Suzuki its quicker. Brace the door openings with hollow section to keep the shape and take all three sills off. You will have to let in new metal on the edges of the floor pans down the length of the car and front and back because it will be rotten were it attaches to the sills and front and rear bulkheads.  The floor that attaches to the centre tunnel is more often than not ok it all depends on how much waters been sloshing around under the carpets. The rot in the sills is impossible to get rid of with out replacing the lot but in the end it will be a strong mint shell. I can tell your not phased by the work. :)Lets have some pictures of her with the carpet out.

Called Suzuki in Greece, gave them part codes and the guy at the parts department asked:

'what car are these codes for"

I replied "Cappuccino"


he came back with an even better question

"WHAT'S THAT"


I said "ok, thanks a lot, bye"

;D

Its pretty much the same in England ;D

I would expect for the guys in Suzuki dealerships in England to know about it, after all it was officially imported even for a short period of time ??)

Took me 1 hour to take seats-lower dash and carpet off, the carpet is a B!tch to take off the car....


anyway, this is what lies beneath...



















I'm getting too old for this sh!t ;D

Despite the fact that I can afford an easy ride, I always opt for the difficult one... ::)

That don't look too bad. The metal on cappos is that thin it doesnt take a lot of rust before its rotted through. Are you stipping it down to a bare shell?

bare as a new-born baby :D

in 5 mins more pics...

Bonnet off....bootlid off....door cards off.... mirrors off.....boot upholstery off....rear bumper off....

Mine currently looks like that!

What panels are you going to order? Sills? rear lamp housing,wheel house panels?

Lord,

we need your gallery updating with your resto progress!

Might have to start a gallery myself soon.

Andy

“ Quoted from Cappo, posted Friday, December 4th, 2009, 2:24:42pm at here ” Lord, we need your gallery updating with your resto progress! Might have to start a gallery myself soon. Andy

Me too. ;)

As I mention earlier, the engine is very smokey. The thing is that the turbo sounds VERY healthy and spools from 2-2.5-3k.Apart from that it looks that it's been fitted recently ??) The rad is also brand new ??)

I also noticed that there's oil residue in the rad. So the smokey engine might just be a case a blown head gasket.

When I'll take the cylinder head off, I'll check for wear on the cylinders(with a proper tool off course) and play on the pistons. If everything's normal, I'll just change the gasket and hopefully that's it.

BTW, the turbo might soon be up for grabs.

Forgot to mention.... rear pillar and glass is off, door windows and mechanisms are off, all rubbers are off.... Don't expect any pics today cos I'm really tired.... ;D

Only the Suzuki Sport turbo has the adjustable wastegate.

Driveshaft out, fluids out, loads of crap out....

The car should be registered as maroon, not silver....

You know having looked at these pics....GULP... i realize I've got a lot of work to do! I've already told my family I dont believe in Christmas anymore! You know it's bad when you would rather buy cappo parts rather than pay a shitty council tax bill.

Back to the cappo... How are you going to treat the sub frameds and the rear of the car..? Like the wheel House underneath.. The rust looks bad to me..or is it? Can that be salvaged? or is it new panels?

Everything can be salvaged ;D

I'm going to post the whole process in pictures. Mind you, i'm going to use double the thickness.

The subframe is totally salvageable, it just looks bad ;D You'll see in my next updates

What pisses me off thought it's not the fact that I have to fix all those things, but the time it'll take me to drive the car... :(

your sub frames are very similar to mine...This gives me hope.

See my album. LORDS CAPPO for my pics..

Hope is the right word mate :)

just took the engine and the gearbox out btw....

Hope you've got a sand blaster hidden away somewhere in that bleedin great workshop ..... 

I actually do ;D But it's only big enough for pieces up to 80cm in length and 40cm in height and width. For bigger things(like bodyshells ;) ) there's a guy 150 yards from my workshop/company/garage . His average day includes 2-3 trucks for sandblasting.... :o

To give you an idea on cost, he charges 150 euros for a complete Unimog Cabin and platform

It shouldn't be more than 200 euros for the Cappo incl the subframes.

OMG! The sandblaster guys down here quoted me 1000-1200¤ for a fiat 500 a few years ago!! Ok, it included heat-projected zinc coating on sensitive areas, but IIRC it still was 800¤ just to get the car sandblasted...

group buy on sandblasting? ;D

“ Quoted from Mac81, posted Wednesday, December 9th, 2009, 9:09:35pm at here ” I actually do ;D But it's only big enough for pieces up to 80cm in length and 40cm in height and width. For bigger things(like bodyshells ;) ) there's a guy 150 yards from my workshop/company/garage . His average day includes 2-3 trucks for sandblasting.... :o To give you an idea on cost, he charges 150 euros for a complete Unimog Cabin and platform It shouldn't be more than 200 euros for the Cappo incl the subframes.

My dad uses the services of a Marine boatyard for his sandblasting needs, they do things like 100 foot yachts, so a shell looks lost in thier sandblasting hanger.....

They sandblasted and powercoated four wheels for my SC100 for £10 :)

that sounds about right. You only need 15-20 mins for both :)

Hmmmm.......  A powdercoating kit is one of those things on my "must have soon" list...  They're quite cheap now although only useful for small things...... 

Also been looking at various plating kits you can use for replating bolts, small brackets etc...

Great thread.
I'm interested in how would you restore the body stiffness after all that rust?

“ Quoted from _andrew, posted Thursday, December 10th, 2009, 8:12:10pm at here ” Great thread. I'm interested in how would you restore the body stiffness after all that rust?

Well thank you :)

All in good time.

I'm going to retract my statement made early in the thread about finished by late January though... I prefer to do the rebuild slowly....surely and WELL DOCUMENTED.

Regarding stiffness...you'll see....very soon  ;)

This is great. Really looking forward to seeing you rebuild the motor! My breath is bated!

been busy taking all the engine ancilliaries off the engine.....

(pics taken with the iphone, therefore the bad quality...)

Moreover, clutch disc is fooked, pressure plate is semi-decent to decent, flywheel is excellent where the clutch disc sits + ring gear is also excellent.

Hi Mac, Great project you have got on your hands. Loving the step by step pics of the whole process.

Just wanted to ask a favour, could you get some measurements of the engine bay and transmission tunnel also distance between the engine mounts. Basicly i have got my hands on a C20xe vauxhall engine modded to 200bhp. Was wondering if i could shoe horn it in my cappo, found a bell housing that you can mount it to a type 9 ford RWD gearbox to.

will do tomorrow mate :)

been at the customs today, customs lady asked me why I imported a write-off ;D

I explained to her that it's "seasoned" and not a write-off. They valued it at 100 euros(excellent news for customs tax)

here we have the trucker staring at the thing of beauty while waiting for the customs lady :)



She also noticed the sponsor on the side and asked me what does it mean... ;D

Thats a Quality sponsor!

Same sponsor as mine!!!!

More pics.....woke up early today...

PS. I'm open to suggestions on the colour.... i don't want silver or red....yellow is "too much" for my taste, blue is too dark....lime green is too "kawasaki"

;D

I'd go for metallic gunmetal grey. Im getting that colour on mine in a few months!  ;D

When it comes time to paining mine, im going for Matte White. Most people dont like that, but i seriously think Matte colours are underrated, probably because most people just use the undercoat as a matte finish. If you want it done proper... Alsa Corp has an awsome 'soft feel' spray (basicly a layer of rubber is sprayed on your car :D).



And ofcourse... theresults on a car :D

Oh my god. I saw that matte finish on a parked Z4 one time... and it was bloody awesome  :o
I'd love to see a Cappuccino painted like that :)

I really like the idea of a matte white finish but wouldn't it scratch easier than the gloss finish?

caterham orange with dark wheels, mmm....

I just finished stripping the car.... Well almost....only the subframes are left...

I'm also pondering with the idea of fitting an S2000 digi dash ;D

btw, i think I have one serious candidate for colour...



Once I finish with the Cappo, it's an AZ-1 next and a Copen at the end... :D

im glad you considered the advice of a confessed banger.....erm classic car guru!