Car 2214 - The building of a Bash Car
© 2009 - All rights reserved.
Surprisingly after 18 months in storage, it started without too much effort and then drove up the ramps onto the trailer under it's own power! Yes, that is Ned Kelly on the bonnet and Yosemite Sam on the tailgate!!!
It is common for these old cars to have tens of thousands spent on them to get them to the Bash and keep them running year after year!
The Valiant arrives in Sydney October 5th, 2009
Bonnet is sanded back as is the rest of the car exterior (yes Ned and Yosemite are now gone). The small dents are hammered out and filled. Bonnet ready for priming.
Some of the Panels are sanded back to bare metal.
Bonnet has been sanded and primed ready for second coat. The rest of the sanding was completed today and any minor dents filled and sanded. The car was masked up ready for the respray. The primer coat will be applied next week. End photo on the right above shows the engine on a knock up stand that Peter welded up today.
Car has been completely primed by Nathan. The roof has been painted white to reflect the outback sun and keep the car cooler. Nathan and Peter remove the tape masking the chrome trim around the roof. The Motor has been pulled down, the rocker cover and sump removed, degreased and washed. The head has also been removed and all parts will be checked, rings replaced etc. before being re-assembled.
Car has been remasked to protect the white roof and interior. The final body coat is applied by Nathan. Peter takes apart the head and removes the valves to check and reseat them. Andrew, Christopher and Kyle are kept busy spray painting the manifolds & rocker cover, sand back some other miscellaneous body parts and build the boot platform that covers the spare tyre well.
The final body coat has had time to dry and the masking is removed.
Today, we started to re-attach the chrome trim such as door handles, badges and door strips. The chrome roof guttering was polished today also.
Today, we made some great headway and managed to attach the front grill and headlights. We have attached the new "door belts" - which are the fury things that wipe the window as you wind it up and down. We inserted all the new rubber door window channels (they're called bailey channels - apparently) AND we attached the new rubber door seals.
Another huge day today with positive progress - although a little slow.
Thanks to our friends at Repco Bankstown, we were able to pick up a nice steering wheel and centre horn button for the Valiant. The only drawback was that there is no "boss" commercially available for our model Valiant. For those of you who don't know (and for the record... I didn't!!!), the "boss" is the part that adapts a steering wheel onto the steering column and allows the wheel to actually turn the steel rod that runs down the centre of the steering column! Live and learn!!! Peter, of course, decided he would make a "boss" for the new steering wheel by cutting the one out of our old steering wheel and using the lathe at Morris Powerlec, to create a "boss" for our new mahogany steering wheel. Well, though it took most of today, he did it, and I must admit, it's a fantastic job!!! Looks just like a bought one!
While Peter was using his engineering brilliance to create the boss, my job was to make headway with the wiring under the dash. After spending the first 3-4 hours trying to understand the wiring diagram in the manual and comparing it to what I was seeing (or supposed to be seeing), I soon discovered that the job was going to be bigger than I thought! Progress was made however, and 12 strands of cable laid from the engine bay, through the firewall and into the car. Existing cables checked and repaired, where necessary. We wired in a new fuse box, master accessory power switch and "live" terminal box for quick connections for all accessories in the future. Kyle (Peter's youngest son, car enthusiast and workhorse), made a plate for the "switch bay" which houses all the illuminated switches for powering up the flashing lights, navigation gear, airhorns, smoke machine, ejector seats and .30 calibre machine gun..... (Okay, I'm kidding about the last 3 items - unless we can pick them up cheap on eBay!!!)
The car is starting to take shape as more is added each week.
The new door trim, black door surrounds (seals), steering wheel and
The new mahogany steering wheel You can see Peter's "boss" in black behind the wheel and some of the wiring in progress under the dash
As you can see, we've added some serious noise makers to the car!
Then and Now!
All themed up for Australia Day!!!
Major milestones achieved today!
The electrical cabling was laid throughout the car with 13 new power cables run to the back of the car and 12 run up under the dash through the firewall. The main power source was wired up to a "master switch" which then powers an illuminated switch panel under the dash This panel controls power to the amber flashing lights, rear driving light, air horns, navigation system, electronic rally trip meter, and supply power to the rear cigarette lighter socket (which will be used to run the refrigerator).
The steering wheel "boss" was finished off today and the wheel was bolted onto the steering column.
The air horns were mounted under the bonnet and we found the make a heck of a lot of noise!
Our new carpet was laid over the underlay
Peter has been busy over the last couple of weeks and the motor has just about been rebuilt as you can see in the first photo! The Tailgate and rear tailgate window has been fitted as have the side mirrors. A new rear tailgate seal has been designed, made and rivetted on by Peter, and he is justifyably impressed with himself! Andrew has fitted the seat belts, the new Pioneer stereo in the dash and rear driving lights on the back roof bar. The horns have now been wired up and make one heck of a noise.
The engine is just about ready, and this week we have had
step in to support us by servicing our automatic transmission at no cost! This has been a huge help since neither Peter or Andrew have had any experience in transmissions!
The rear seat has been mounted and in the next week or two we expect the transmission, motor and driveshaft to be put back into the car.
It has been a great two Saturdays with some excellent progress. The torque converter has been mounted on the motor and the carburettor rebuilt. Peter's youngest son - Kyle has started building the roof mounted cage rack to sit on top of the roof racks.
New wiper blades have been fitted to the wiper arms and the distributor completed and mounted on the engine.
Oh! Almost forgot! We finally sourced our mag wheels as you can see! They arrived this week from Queensland!
What a huge couple of days!!!
Next week we plan to connect up the engine wiring, insert the driveshaft if it is ready, and rebuild the front brakes. this leaves us the exhaust and windscreens prior to testing and then registration. With a bit of luck, we should be starting the engine in 2-3 weeks time!
Well, again a big couple of weeks. Lots of major "ups" and a couple of minor "downs"...!
Hi-Torque completed the driveshaft and we installed it as planned. It was perfect! Peter built the driveshaft safety frame which is a requirement of bash cars and bolted it in place. The safety frame prevents the drive shaft from dropping onto the ground if one of the joints breaks during the rough journey. A broken driveshaft can quicly act as a "pole vault" and flip the car if travelling at any sort of speed.
We found out "the complete rubber kit" that we purchased for the car has everything EXCEPT the side wagin window rubbers! After speaking to the supplier we found out that nobody has made the side window rubber seals in years. We were told that we may get lucky enough to get some second hand ones!!! The car is 43 years old. We don't fancy our chances. Now we have put off the winscreen replacement until we can solve this small issue.
More UP's..... After sending few emails a couple of days ago, we stumbled across Valiant Restoration company in SA that has informed us that the cargo bay windscreen rubbers can be sourced from a manufacturer in Adelaide and one in Brisbane. We will be on the phone to them on Monday!
We don't have any photos for this peiod as the changes were subtle ones and unfortunately, photos really do not do the work true justice. Due to prior committments, our next session on the Valiant will be May the 15th.
It has been a great Saturday. We have mounted the kick down cable, fitted the new steering linkages, blew out the brake lines and reconnected them all ready for "bleeding" next week.
The transmission cooler was also fitted and will be connected up next Saturday also.
It has been another great Saturday. The brakes have been bled. The fuel tank removed and cleaned out. We fitted the rubber fuel tank protector under the car to avoid the tank being punctured by any loose stones.
We replaced the engine oil with the thicker oil as suggested by Castrol and the car ran much better. The transmission sump was removed as we had discovered a slow leak. The sump was then resealed and refitted.
The car was driven up and down the street for testing. Performance is rather wanting due to the timing (we hope). Unfortunately, our timing light was not working and we have to get a replacement so we can tune the car next Saturday.
The windscreens fitting was delayed but they are expected to be fitted during this coming week.
"Houston.... We have a problem!
We took the car for it's first drive today! 3 short runs just to see how it sounded and performed. We will definitely have to check the timing and certainly get the wheels aligned but all signs were great. Castrol has suggested we replace the oil with GTX as it is better for older cars, so we will do this next week. The transmission cooler was also mounted this week.
The windscreens will be fitted during the week, so the next photos will show the exterior of the car complete.
It has been another great couple of weeks. I wont bore you with the details but in short, Milton from Harris Engine Services in Revesby completed the work on the motor on time as promised. We bolted the head back on, reattached the transmission and the manifolds. We dropped the motor back into the car and wired it back up on Saturday 19th. Milton from Harris Engines came by during the evening of Monday 20th June to help with tuning.
We have now completed the following:
We are now ready for registration!!!
The car is now registered and insured and just about ready to go! We still have a few minor tweaks to perform over the next couple of Saturdays but we will certainly be ready for the Virgin Bash at the end of this month.
Today the car was in Milperra for a photo session with tha local newspaper - the Canterbury Bankstown Torch who will be publishing a story on the MIB Bash Car in the next week or so.
We have attached the preliminary sponsor stickers to the car and we are pretty happy with how the Valiant has turned out.
This coming Sunday, Peter will take it for a trip down to Wollongong just to see how it runs. Personally, I'm interested in hearing how it handles coming up Mount Ousely!!!
The Wollongong trip was a success and the car performed faultlessly!
The Torch newspaper article appeared today as promised by the publisher!
Final touch ups completed. Harrison Engine Services tuned the carbie for us. While at Harrison's, Milton chained down our engine (a bash requirement) and did a quick check on it for us. Thanks Milton!!!
We have fitted the Cargo Barrier (a Bash requirement for station wagons). We have sealed the air vents to prevent dust entering the car. We now have ALL the electricals functioning and have added some neon lights to light up the dash at night. We have added auxilliary power outlets at the front of the car 3 x cigarette lighter power outlet points and 1 x USB power outlet to power the GPS, mobile phones etc. We resealed the exharst and inlet manifolds to elliminate a tiny exhaust leak we had. Peter "torqued up" the front torsion bar suspension to get a bit more height at the front end. the locks were changed along with the ignition barrel. The headlight protectors were fitted and we mounted the fire extingusher and loaded all the spares, the first aid kit and the Black Rat Recovery Kit in the car. The extra sponsor stickers were added and to finish, any paint chips were touched up.
All that is left is:
CAR 2214 was "on show" at Milperra Shopping (Amiens Ave) centre on Friday 23rd July. It will also make an appearance at Milperra Shopping centre (Bullecourt Rd) in the next week or so. It will also be "on show' at the Network Building Supplies open day Friday 6th August.
The next update to this website will be after the Virgin Day Run and scrutineering day which occur on the 30th July and 1st August.
Yes, we have passed scrutineering with flying colours and our car is now good to go on the 2010 B-Shed to Byron Variety Bash
The car has been modified for some extra power.
The Valiant completes the 2010 B-Shed to Byron Variety Bash!
After the 2010 Bash, it was decided that the car needed some modifications in order to increase safety and survive future Bashes. These modifications are listed below:
Sadly, due to personal reasons, Peter Bonselaar has regretfully decided to pull out of the Bash car and not continue doing the Variety Bash . His ingenuity and engineering skills will be sorely missed. As a result, Andrew Georgiadis will be buying Peter's half of the car.
I have taht the Men in Black theme had a small problem of trying to carry out repairs on the road while dressed in a suit!!! And, let's face it, the 2011 Bash through outback Australia to Broome will be a very uncomfortable ride in a non airconditioned car while dressed that way! As such, I have decided to retheme the car as TROJANS.
The steel transmission cooler lines have been fitted and one of the leaking transmission cables that has
The dual master cylinder has been fitted and dual circuit brake lines to separate the brakes into a front circuit and a rear
circuit - for safety.
The car has returned from The Ultimate Suspension. All I can say is WOW! Thank you to Ken at The Ultimate Suspension for all the help and support.
Due to the new height of the car, I have decided to redesign the roof storage. The Jerry cans will now face 90 degrees to the original configuration and can be easily pulled out from the sides. They will sit midway on the roof rack over the back pillar.
Did you notice the new number plate?
The front bench seat - though original and pretty, is really impractical for the Bash for three reasons: 1) they are vinyl and one tends to perspire when sitting on them - especially in the warm outback. 2) When taking a curve at speed, one tends to slide from side to side, and 3) There was no room for a centre console for storage.
With the help of the crew for Car 800 "Spartans" and Geoff, we managed to knock it over in a day.
The seats are even colour coordinated! Now we have to design and build the console.
The centre console has now been built and the new switch panel with all the electrical switches has been moved from under the dash in front of the navigator and is now mounted on the console for easy access by both the driver and navigator.
There are no new photos to show at the moment because I forgot to take them. Rest assured, the photos will be updated soon!
I am currently organising a new Limited Slip Diff which will be fitted to the car sometime in May. I have been told by those in the know, that it will be more "fun" around corners on the dirt.
Once the diff is mounted, then all that is left to have the vehicle "Bash ready" will be a couple of minor things which I wish to address. These include:
The car is off to Trundle for a mini Bash on April 16th which has been organised by the NSW Fire Brigade Bash Team. I will ensure that pictures are posted on this site from that event.
I have mounted the new HID Driving lights on the roof.
The car has had some of the new sponsor stickers placed on it and the Trojan Horse Head is almost ready and has been mounted on the car in time for the big fundraising night.
have generously donated a bonnet wrap for the car. rather than explaining what that is, it's easier just to show you a picture............!
At this point, I need to now further protect the gear cables by adding more insulation and finally, the car needs to go to a brake specialist in order to get the drums machined and the brakes radius ground to stop the slight pull to the left under brakes. After that, the car will be ready to run in the 2011 Bash. The only possible change is to replace the entire transmission to a linkage system rather than the current cable unit. The issue with that idea is that it is hard to find the correct transmission that will bolt to the engine. If we find one, then great, if not, then the car will run with what it has!
The brakes have been machined and radius ground at Brabond Brakes in Peakhurst. New slave cylinders and retaining springs.
A second-hand VC model diff was purchased from Riverston Spares (they have parts for so many old cars it's unbelievable!).
It has been decided to change the transmission to a more reliable later model slip-yolk type. This means the driveshaft needs to be replaced. This now has the concertina effect of making the rally trip meter probe (which was located on the drive shaft) ineffective.
The fresh air intake system has been modified in order to allow access to the rear driverside door. During the last bash, the airintake design made the door unusable. A more flexible system has been made and now all four doors are useable.
Re-Nu auto transmissions have located a replacement transmission and driveshaft.
The driveshaft safety support has now been modified to prevent the driveshaft from going through the floor of the car or into the ground in case of breakage. A ring has been welded to the original set up which has secured the shaft from any dangerous movement.
The exhaust pipe has been re-routed from pointing to the rear of the car (and slowly melting the passenger mud flap) to now pointing to the side of the car between the wheel and the rear bumper.
The air intake on the carbie has been replaced from a paper filter to an oil impregnated foam UniFilter system that George was able to source.
Tomorrow is Scrutineering Day, so today Geoff and I will be preparing the car, loading it up, ready for tomorrow.
24/07/11 - The car has again passed scrutineering. The scrutineers did suggest that we restrain the motor from forward movement to protect the radiator from the fan in case of any forward engine movement.
25/07/11 - The frayed accelerator cable has now been replaced and the engine has been retrained. The sump guard has had a rubber baffle fitted to prevent rattling and a new temperature gauge sending unit fitted. Finally, the plastic fuel filter has been replaced by a glass one.
26/07/11 - The car has been back to The Ultimate Suspension for a check and tighten of all suspension components. The car was then taken back to Brabond Brakes for a final adjustment.
27/07/11 - The tailgate lock needed to be fixed so it was taken to the local locksmith for this quick job.
The car was dyno tuned today. It cruises on the highway easily at 110kph.
Friday we will mount the Trojan Horse head and the spears. We will pack the pallecon and wash the car and then take it to The Ultimate Suspension for a quick photo shoot.
The new door trim has arrived and will be attached in the next week or two. We expect to have the seats up from Melbourne mid December.
The new mahogany steering wheel You can see Peter's "boss" in black behind the wheel and some of the wiring in progress under the dash
Car 2214 - Raising money for special needs children
We have arrived back from Broome and the car performed without any issues whatsoever.
The car has finally arrived back in Sydney and was picked up from the Chullora Depot.
We hit the car with a high pressure water cleaner and removed most of the dust and dirt. As you can imagine, our driveway was red and muddy by the time we finished.
At the end of November, the car was sent to The Ultimate Suspension in Ingleburn where they removed the suspension, replaced all the bushes and checked the entire car. The guys then reinforced the shock towers and made sure everything was OK and ready for next year's Bash to Cape York.
Thanks to the guys at The Ultimate Suspension for all their work and care in preparing and maintaining the car.
The car is scheduled to have a new air conditioner fitted around the end on March. This year we plan to do the Bash in a little bit of comfort.
As planned, the car has been delivered to Frosty Auto Air, where Phillip from the B1B2 Variety Bash Car (Bananas in Pyjamas) started work in fitting the air conditioner.
While there, Pillip found a leaky Welch plug on the motor and has replaced it with a new brass one.
Fitting the airconditioner will take some time as the radiator has been removed to access the fan in order to remove and modify it. The front panel (circled in red), needs to be cut out to improve airflow to the radiator and condenser. There are a few modifications to do, but I have the best guy doing the work and I have no doubts we will be cool and comfortable on this next Bash!!!
Once Phillip is finished, there are a couple of minor modifications and then we are basically ready to go! Only 127 days to go before the start of the 2012 Bash!
All the work is now complete and the car is readu for the 2013 Bash.
We have added a compressor to pump air into the distributor in order to pressurise it to help prevent wtaer entering it and causing the car to stall during creek crossings. We can also use the same compressor to inflate tyres!.
Our great mate Phillip from car B1B2 has replaced the old fan with twin Thermal fans to oprevent the car overheating during idle - which proved to be a big problem in the past during daily Bash starts where we would be slowly making our way to the starting arch. The fans will be tested on the next bash!
This page last modified on Tuesday, July 09, 2013