Roof and windscreen surround

Lead Lined GT6 surround
A bad state of repair, GT6 Screen surround

this is one of the jobs I had dreaded the most.  The leading edge of the roof and the full windscreen surround are badly in need of replacment.  If if goes wrong then I will either not be able to get the screen in or the roof will look uneven, and the guttering looking bad.     Here goes……

My pre repair GT6 roof leading edge
Full of filler and lead. The two did not mix well either
Badly corroded GT6 scuttle
The whole screen surround and roof edge looks like it needs doing
I used a spitfire Mk4 windscreen surround to replace mine as it was very bad.  
At the time there was also a front roof repair panel available.  However, I think I purchased one of the last available.  I understand the one popular alternative methods is too fabricate the roof panel out of an old style Mini rear valance panel.
There is a guy out there that will taylor it and fabricate it for you in a few days.  ( http://www.tssc.org.uk/index.php?option=com_fireboard&Itemid=55&func=view&id=56472&catid=195#56472 )
I started by cutting the roof back to about the join location of the new panel.  Then removing the screen surround as can be seen below.
Then get the spitfire surround welded in place.  The top corners will need to be built up slightly to meet the roof corners.  (about 1cm at the outside corners. http://mygt6.com/images/IMAG0194.jpg )
then ground back to smooth.
Then next stage was welding a strip all  the way along the top of the spitftire panel for the  roof panel leading edge  to clamp and weld too.
I also had to repair the front side guttering’s.  This involved bending and folding some strips to match the profile of the gutters in place.  That then welds too the corners of the screen that you will have built up as above.
Then is is really a case of making sure the roof panel is all lined up as you want, tacking the front edge on and then the rear edge where it joins the old roof. (care must be taken at these edges due to the heat being put into the steel.  It is all to easy to distort the panel at the final hurdle and then set you back many hours and too make the final result no as pleasing the the eye)    Stitch weld only taking time at low current for the stell too cool between welds…
Then I trimed the leading edg to a nice curve that sits well with the roof.   Fold the side guttering up and over the roof edges and blend / weld to the old guttering.
Now its really a case of Filling and sanding until you are happy with the finish.

GT6 Rear suspension

GT6 Rear suspension setup
This was the state of the rear suspension after body removal.
GT6 Differential gleaning
A rare oppurtunity to see a Ruggles at work in the wild
GT6 rear lower wishbon refurbed
GT6 rear wishbone, re-bushed painted and new truninons fitted. DONE....
GT6 vertical link and shaft rebuilt
New bearings, Rotoflex, slave cylinders, shoe adjusters, UJ's. DONE,,,,
GT6 rear rotoflex Suspension
GT6 Differential, suspension and brakes fully serviced and assembled.

The suspension was assembled as pictured above, but was subsequently stripped and I fitted a lowering bracket, Gaz shockabsorbers were also utilised.  While apart I wanted to get rid of the old Rotoflex driveshafts and replace them with the Canley Classics, CV jointed drive shafts.  The Idea behind this was to extend the life,  reduce the servicing needs and reduce the risk of catastrophic failure that  the original shafts can suffer from.

When approaching the job of taking apart rear suspension.  BE CAREFUL.  If you are working on a Rotoflex model, be warned, the rear suspension is under a huge amount of tension.  the spring must be supported with a lever and axle stand if the body is still in situation.  the method I used was to replace the differential studs with longer threaded bar.  Then when all bolted to the rear uprights and wishbones, tighten the spring down in situ with the longer studding in the differential.  I used this method due to a lack of weight on the rear of the car due to no tub, glass and trim being present.

New Parts fitted.

Leaf Spring.  Gaz Shock absorbers.  3/4 lowering diff spacer.  Brake shoes.  Shoe fitting Kit.  Brake Adjusters.  brake Slave Cylinders.  Wheel Bearings.  Universal Joints.

Front Suspension

GT6 Front Suspension as removed
this is the front suspension corner as remover, uuugghhh……

Gt6 rebuilt front suspension
Stripped, painted, re bushed, new bearings, new trunions, new ball joints and new disk. Done

GT6 front near side corner fitted
fully re built front nearside corner

Both front corners received the same treatment.  Fully stripped, painted,  Re-bushed, new trunions, new wheel bearings, new disks, new top ball joints, New Shock absorbers, new Springs, new track rod ends, new steering rack and new Anti roll bar.

GT6 door repair

GT6 lower door skin removed
The bad area of the GT6 door skin was cut away.

Gt6 door frame repair

Door frame repair to lower corner
GT6 lower door skin tacked in place
GT6 lower door skin tacked in place

One door needed quite an extensive repair.  The lower part of the frame was nearly all corroded away.  the rusted and thin metal was all cut away.  then a new door floor was fitted. The lower front corner was fabricated from two plates. (As above)  Then the lower door skin was tacked in place before the skin lip was folded over .

Trial door fitting
repaired GT6 door being hung to check fit.

Upon completion, the door was hung on the tub to check fit and door gaps.  The GT6 door seems to fit as well as it did before I took it off.  So I hope there is wiggle room to taylor it after paint.

repaired GT6 door in primer
The door primer

After re skinning the GT6 door, it was skimmed with Upol gold stop filler the given a few coats of high build primer.  Then the skin was flattened with 800 grit on a DA sander.

The GT6 Information, Restoration,and Documentation Site.