BE 646

dkp_cobra · March 21, 2011, 16:17:16

This thread describes my attempt to restore my AC Aceca BE 646. The journey started on 2011/03 and after nine years it's still not finished but I'll try to keep on doing it.
In the meantime the new AC Aceca owner David (https://www.acownersclub.co.uk/forum/index.php?action=profile;u=28224) started to make an index and a table of content for my thread. This is a great (and painful) job and he allowed me to use his work to publish it here. This is a very helpful document and I would like to thank him very much. Thank you, David.

RESTORATION OF BE646 2011 - TO DATE (26 December 2023/Msg 423)

TABLE OF CONTENTS

The pages are hyperlinks. Click them you will like it ...

# = message number (p. x-y) = number of photo in separate document https://c.1und1.de/362516207/Qk7IjtyMTCmCqPrexFGo5A
Page 1:
#2 (p. 1): left side in fwd cabin
#3 p. (3-4): inside right hand door
#4-6: wood repairs
#7-11 (p. 14/455): speedometer drive, parking brake handle
#12 (p. 13/455): Ford 289+toploader
Page 2:
#20: Aceca as bought
#25 (p. 19/455): cabin overhead light, panels behind seat, rear frame
#28 (p. 20-21): rear frame
#28 (p. 22): fuel tank mounting and rear frame
#28 (p. 27-28): engine compartment looking fwd and backwards
#28 (p. 29): front disk and caliper
#29: motor weights
Page 3:
#30-31: motor weights
#33-36: (p. 32-35): seats
#36 (p. 36): fuel tank
#37: tail lights and body
#40 (p. 43): right B pillar
Page 4:
#46 (p. 47-48): left B pillar, rear framing
#52 (p. 50-52): frame and rockers
#54: hand brake
#55 (p. 53-58): rear framing
#57 (p. 59): front framing
#58: A pillar
#59 (p. 63): footboxes, dash etc (RH drive), rear frame
Page 5:
#60-61: tachometer drive
#62 (p. 63-66): rear frame and differential etc
#65 (p. 68-69): rear body, B pillars
#68: differential
#69 (p. 70-71): MGA heater
#70 (p. 72-73): wiper wiring
#71 (p. 73): seats
#73: differential brackets
#74, 77 (p. 76-81): windshield wiper motor and mechanism
Page 6:
#77: wiper R and R
#78 (p. 83): driveshafts (MkIV, new Aceca, original Aceca)
#82 (p. 88-96): Jag differential mounting etc
#85-87: stub axles
#89 (p. 97): horns
Page 7:
#90: horns
#91-93 (p. 99-105): Jag differential mounting
#93: differential mounting
#94 (p. 105-110): mounting 289 and toploader
#96 (p. 112-113): pedal box, washer wheels
#97 (p. 113-119): engine mounts
#97-104 (p. 119-123): steering gear
Page 8:
#105-107: steering conversion discussion
#108 (p. 124): seat redo
#109 (p. 125): rack and pinion mountings
#112-113: frame strength measurement/analysis
#114-119: (p. 130-140): steering discussion and X-ray
#114-119: rack-and-pinion mount
#119: rack and pinion conversion
Page 9:
#120 (p. 140-151): steering column bracket, differential, half shaft, transmission-mounts
#122: gearbox bracket
#123: ACOC badge R&R
#124: converting Holley carburetor to manual choke
#125-126: speedometer drive
#127 (p. 157-158): headers, door fix, hatch
#128 (p. 158): hatch
#129 (p. 164): heater vents
#132 (p. 167): clutch and brake fluid reservoirs
#133 (p. 169-170): frame modifications to fit motor and gearbox
#134 (p. 170-171): bumpers
#134 (p. 172-173): motor mounts
Page 10:
#135 (p. 176-177): steering shaft
#136-138 (p. 177-186): LH drive dashboard
#138-141 (p. 187-190): differential bracket
#141 (p.191-194): dash binnacle
#146 (p. 195): parking brake handle
Page 11:
#151-152: re-chroming
#152 (p. 199-200): cabin light
#153-156 (p. 201-213): dash and footbox modifications for 289
#157 (p. 216-220): headers
#158-159: dash, glove box
Page 12:
#165-166 (p. 221-238): dash and footbox modifications
#168 (p. 239-240): differential rebuild
#169 (p. 240-243): rear view mirror
#171 (p. 243-245): differential rebuild
#171-172 (p. 246-252): footboxes and pedal box
#172 (p. 252-253): foot box air vents
#178 (p. 254-255): transverse brace for preventing engine mount rotation (note that mounts are clamped, not welded to the frame to be able to change motors)
Page 13:
#181 (p. 255-261): footbox modifications
#181 (p. 261-267): borescope examination of inside frame tubes and discussion of strengthening needs
#187 (p. 271-273): removing running gear/A arms/suspension
#189 (p. 276): stripped body
#190 (p. 277): differential gears
#192 (p. 278-280): stripped body including inside roof above doors
#194 (p. 281-286): improved engine mounts
Page 14:
#196 (p. 287): reproduction VIN plate
#197 (p. 288): footboxes
#197-202 (p. 288-309): frame strength analysis and reinforcing tube insertion
#202-204 (p. 312-317): another improved engine-mount to brace frame alignment
#205 (p. 318-321): closing frame holes
#206-207 (p. 322-325): rocker repairs
#208 (p. 326-331): rear frame (behind seats) repairs
Page 15:
#210 (p. 332-333): discussion about removing rear of body
#211-213 (p. 334-338): rear frame repairs and how to do them
#216 (p. 342-345): shock absorber brackets & others
#217 (p. 347-348): bracket for spare wheel fixing rod
#218 (p. 349): rear subframe complete
#219-221 (p. 350): fitting fuel tank, repairing frame to suit. Discussion of A-arm bracket alignment misalignment etc
#222-224 (p. 356-366): right and left rocker repairs
Page 16:
#225 (p.366-369): frame repairs behind seats, fitting fiberglass panel
#226 (p. 370): seat runner supports
#226 (p. 370-372): B-column brace
#227 (p. 372-374): rear subframe installation
#228-229 (p. 375-380): improved engine mounts, drive shaft protection loop
#231 (p. 380-385): rocker panel repair and replacement
#232-233 (p. 385-393): door fitting, hinges, and B pillar repair
#234-238 (p. 394-400): B-pillar bracing panels
Page 17:
#239-244 B pillar bracing panels
#245 (p. 400-403): rocker covers
#246 (p. 404-405): fuel tank straps
#247 (p. 406-410): better B pillar covers
#248-249 (p. 410-414): hatch window
#250 (p. 415-419): front lower wishbone R&R
#251 (p. 420-422): fiberglass panel behind seats
#252-253 (p. 423-429): hatch R&R
#254 (p. 429-455) door rebuilding, fitting, finding car VIN stamped in door
Page 18:
#256-267 door rebuilding and fitting, window frames
Page 19:
#271: front quarter window latches
#273: door fitting
#279: grease gun R&R
#280: door frames and inside panels
#281: seat belt anchor brackets
#282: transmission tunnel
#283: floor panels
Page 20:
#285-291: panels for boot (trunk)
#292: seat runners
#293-294: brackets to fix the panel behind the seats
#294: shoulder belt brackets
#295: Motor change to Ford Zephyr and gearbox, strip
#296: Zephyr cylinder head rebuild
#299: flywheel, clutch plate, clutch cover rebuilds

Page 21:
#300: Ford Zephyr motor and gearbox, installation
#303: doors (foot box modifications, motor changed a Ford Zephyr), boot panels
#304: rear inner wing panels
#305: inner fender screens
#313: floor panels and transmission tunnel (for different transmission)
#314: radiator, cooling fan, inner fender panels
Page 22:
#315: door jamb A-pillar panels
#316: rocker panel reconstruction
#317: "exploded" internal panels
#318: stripped car with rear and roof remaining over frame
#319: rebuilding front frame, Zephyr exhaust routing through floor outriggers
#320: front brake line brackets, ENV differential mounting
#321: removable inner front fender liners, battery tray
#322: Zephyr muffler fitting, pedal box fitting
#323: pedal box construction & fitting, battery tray fitting, heating system
#324: heater installation
#325: Zephyr muffler brackets, exhaust pipes
#326: Zephyr header construction, exhaust pipes
#327: A pillar base reconstruction
#328: heater duct parts, pedals and pedal box, master cylinders
Page 23:
#331: brake rotor dust covers
#333: body panels below A pillars, leaf spring strengthening
#334: JOKE about stripped frame
#335: painted frame, beginning body reassembly
#336-337: frame coating discussion
#338: rear spring, modified front spring
#338: new front spring mounting brackets, front and rear spring reassembly
#339: wheel size
#340: differential parts and reconstruction
#342: differential seal fabrication
#344: front and rear axle disassembly
Page 24:
#345: rear hub problems
#346: rear brake disassembly, lubrication, new dust covers
#348: heat wrapping exhaust manifolds
#348: hubs, spindles, and uprights back from painter
#349: hand brake cables and ferrules
#350: header gasket fabrication
#351: parking brake mechanism and restoration
#352: parking brake parts source
#354: wheel spinner restoration
#355: assembling rear hubs with new seals and brake linings
#356: modified brake bleeders
#358: reassembly of front hubs and brakes
#358: dashboard reconstruction including instruments and glove box
#359: return of complete body from body shop
#358: headlight alignment
#359: location and installation of front turn signals and bumper with overriders
Page 25:
#362-363: bumper over riders and mounts
#363: battery tray mounted
#363: clutch and brake lines
#363: steering column and accelerator pedal
#364: pedal box and hydraulic cylinders and lines
#365: heater and ducts
#366: demister and heater installation
#367: cabin, dash, and transmission tunnel panels
#367: complete external views of body
#368: new boot panels
#368: fitting fender liners
#368: new seats and installation
#368: horn button
#368: fitting hatch
#369: comparison of old and new interior panels
#370: steering column R&R, installation
#371: bonnet rebuild and installation
#371: motor installation
#371: heater and hose arrangement
#374: differential installation
#374: fuel pump mounting and installation
#374: windshield wiper rebuild and installation
#374: right side heater, bracket, and vent arrangement
#374: steering wheel and hub
#376: discussion of Zephyr displacement options
#377: dampers, hubs, drive shafts and steering
#377: body refitted to frame
#378-379: shortening gearbox
#380: new parking brake construction and fitting
#380: shift knob modification
#382-383: Zephyr flywheel cover and crankshaft
#384: gear box installation
#384: new transmission tunnel
#384: parking brake details, completion, and mounting
#384: dashboard views
#385: Zephyr flywheel cover discussion
Page 26:
#387: door panel construction
#387: right angle speedo drive adapter
#389: rear fender undercoating discussion
Page 27:
#390: fuel tank construction and testing
#391 Aceca model
#392: fuel level sender
#392: comparison of old and new fuel tanks
#392: fuel filter, fuel pump mounts and fuel line
#392: exhaust pipe hangers and routing
#392: fuel filler cover
#392: rain gutter construction
#393-394: fuel tank construction
#396-397: fuel tank lines and fuel pumps
#398: motor installation and motor mounts
#398: inner front fenders and wheel well liners
#399: front fender stone guards
#400-401: Aceca project history
#402: fresh air vent and hoses
#403: door latches, badges, grease gun, screen washer, Reservoirs, mirror
#404-406: taping leaf springs
Page 28:
#407: dimple dies
#407: coolant overflow tank mounts
#408-410: header tank discussion
#411: heater valve and hoses
#411: heater and ventilation controls
#411: fuel lines and carburetors
#412: speedometer cable
#412: exhaust manifold mounting and wrap
#412: hatch stays and mounts
#412: throttle linkage
#414-417: exhaust heat wrapping and discussion
#417: hatch window surround
#417: hatch mounting and hinges
#418-421: lambda sensor on exhaust, air/fuel sensor
Page 29:
#422-423: leather for dash covering
#423: door card covering
#423: glove box
#423: driving light mounts
#423: carpets
#423: seats
#423: door installation
#423: door locks
#423: seat mounts
#423: threshold covers
#423: door windows
#423: rear quarter window mounting
#423: driver's outside mirror mounting

OK, let's start ....

Gus Meyjes · March 21, 2011, 20:25:08

Oh brotherly love! And with some fine onlookers in the back ground!!

Gus

dkp_cobra · May 12, 2011, 16:53:53

RESTORATION OF BE646 2011 - TO DATE (26 December 2023/MSG 423)

SUBJECT INDEX

# = message number (p. x-y) = number of photo in separate linked pages at
https://c.1und1.de/362516207/Qk7IjtyMTCmCqPrexFGo5A

PART 1/2

Battery Box
#321: battery tray
#323: battery tray fitting
#363: battery tray attached
Body Panel Repairs
#189 (p. 276): stripped body
#192: stripped body
#210 (p. 332-333): discussion about removing roof and rear of body
#318: stripped car with rear and roof remaining over frame
#192 (p. 278-280): stripped body including inside roof above doors
#317: "exploded" panels
#196 (p. 287): reproduction VIN plate
#403: chassis plate mounted
Body reconstruction
#335: beginning reassembly
#377: body refitted on frame
A Pillars
#315: A pillar repairs
#327: A pillar reconstruction
#333: body panels below A columns
B Pillars
#40 (p. 43): right door jamb
#65 (p. 68-69): door jambs
#226: B pillar braces
#232-233 (p. 385-393): B pillar repair
#234-238 (p. 394-400): B pillar bracing panels
#239-244: B pillar bracing panels
#247 (p. 406-410): better B pillar covers and bracing
Bonnet
#157: before and after repairs
#371: rebuild and installation
Boot (trunk) panels
#46: repairs needed
#285-291: making panels for boot
#294: old and new boot panels exploded
#303: boot panels
#305: boot panels and spare wheel cover
#368: boot panels including floor
Fender panels and screens
#304: rear inner fender wing panels
#305: inner front fender screens and wing panels
#314: inner fender panels in front of radiator
#321: removable inner front fender liners
#368: internal rear fender panels
#389: rear fender undercoat discussion
#398: inner front fender liners and mounts
#399: front fender stone guards
Floor Panels
#283: floor panels
#303: floors (Zephyr)
#313: stronger floor panels (for Zephyr transmission)
Panel behind seats
#25 (p. 20-21): panels behind seats
#225 (p.366-369): fitting fiberglass panel
#251 (p. 420-422): fiberglass panel behind seats
#293-294: brackets to attach the panel behind the seats
Rain gutters
#392
Rear Body Panel Replacement
#213
Rocker (Door Sill) Panels
#206: sill repairs
#222-224 (p. 356-366): right and left door sill repairs
#231 (p. 380-385): rocker panel repair and replacement
#245 (p. 400-403): rocker covers
#303: rocker fitting
#316: rocker panel reconstruction
Transmission Tunnel
#282: transmission tunnel
#283: transmission tunnel
#313: transmission tunnel (for Zephyr transmission)
#359: return of complete body from body shop
#359: location and installation of front turn signals and bumper with overriders
#384: new transmission tunnel
Brakes and hubs
#28 (p. 29): front disk and caliper
#320: front brake line brackets
#331: front disk brake covers
#346: rear brake disassembly, lubrication, new dust covers
#355: assembling rear hubs with new seals and brake linings
#356: modified brake bleeders
#358: reassembly of front hubs and brakes
#363: brake lines
Parking brake
#7 (p. 14/455): parking brake handle
#10: description of stock arrangement
#52: as bought
#54: as bought
#56: originality of mount
#134: handle
#146: handle
#186: complete assembly
#349: hand brake cables and ferrules
#351: parking brake mechanism and restoration
#352: parking brake parts source
#380: handbrake reconstruction and fitting
#384: parking brake finalization and mounting
Bumpers
#211: rear bumper brackets
#134 (p. 170-171): bumpers
#362: old and new over riders and brackets
#363 over rider mounting
Cabin
Dashboard
#59 (p. 63): dash etc (RH drive)
#136-139 (p. 177-186): LH drive dashboard
#141 (p.191-194): dash binnacle
#153-156 (p. 201-213): dash
#158-166 (p. 221-238): dash
#291: aluminum dash
#358: dashboard reconstruction including instruments and glove box
#367 new dashboard
#403: rear view mirror rebuild and mounting
#411: dash control installation
#422-423: leather covering dash
Footboxes
#28: RH drive footboxes
#59 (p. 63): footboxes (RH drive)
#153-156 (p. 201-213): footbox modifications for 289
#158-166 (p. 221-238): footbox modifications
#171-172 (p. 246-252): footboxes
#181 (p. 255-261): footbox modifications for clutch lever
#197 (p. 288): footboxes
#303: foot boxes for a Ford Zephyr 6
Interior
#2 p. 1: left side in front of cabin
#25 p. 19/455: cabin overhead light
#152 (p. 199-200): cabin light
#367: new transmission tunnel and cabin floor
#369: old and new interior panels compared
#422-423: covering door cards, glove box
#423: carpets
#423: seats and seat mounts
#423: threshold covers
Parking brake: See brakes above
Pedal Box
#59: pedals
#96 (p. 112-113): pedal box
#171-172 (p. 246-252): pedal box
#172: gas pedal
#186: throttle pedal bracket finished
#322: pedal box fitting
#323: pedal box construction & fitting
#328: pedal box powder coating and assembly
#363: accelerator pedal and linkage
#364: footbox installation including hydraulic cylinders
Rear View Mirror
#169 (p. 240-243): rear view mirror
#423: exterior drivers side mirror
Seats
#33 (p. 32-35): seats
#71 (p. 73): seats
#108 (p. 124): seat redo
#292: seat runners
#368: seats and tracks
Seat Belts
#281: seat belt anchor brackets
#294: shoulder belt brackets
Carburetor
#124: converting Holley Street Avenger to manual choke
#411-412: carburetors, linkages, manifolds, and air cleaners
Differential
#62 (p. 63-66): rear frame and differential, ENV vs Jaguar differentials
#68: weights
#73: brackets
#82 (p. 88-96): Jaguar differential mounting brackets
#89: differential brackets
#91 (p. 99-105): Jaguar differential mounting
#93-94: differential mounting
#120 (p. 140-151): differential, drive shaft, transmission mounts
#122: differential mounts
#139-141 (p. 187-190): upper differential bracket
#168 (p. 239-240): differential rebuild
#171 (p. 243-245): differential rebuild
#186: finished brackets
#190-191 (p. 277): differential gears and ratios
#320: ENV differential for Zephyr
#340: differential cleanup and reassembly
#342: differential seal fabrication
#374: differential installation
Doors
#3: as bought inner right side door
#127 (p. 157-158): door fixes
#232-233 (p. 385-393): door fitting, hinges
#245: door sill fabrication and replacement
#254 (p. 429-455): door rebuilding, fitting, and car VIN stamped in door
#256-267: door rebuilding and fitting
#264: window frames
#271: front quarter window latches
#273: adjustable door brace and door fitting adjustment
#280: door frame and inside panels
#303: doors and window frame mounts
#303: front quarter windows
#387: door panels and structure
#403: door handles
#423: door cards
#423: door installation
#423: door locks
#423: door windows
#423: rear quarter windows
Drive Shafts
#78: (p. 83): drive shafts (MkIV, new Aceca, original Aceca)
#84-85: half shaft sources
#120: Kirkham driveshaft
#312: Zephyr drive shaft
Exhaust
#319: exhaust routing through floor outriggers (Zephyr)
#322: muffler and exhaust pipe fitting (Zephyr and all others)
#325: muffler brackets (Zephyr)
#326: exhaust header construction
#348: heat wrapping exhaust manifolds
#350: header gasket fabrication
#392: exhaust pipe routing and hangers
#412, 414-417: exhaust pipe wrapping
#418-421: Lambda sensor, air/fuel monitor (see also instruments)
Frame
#5 wood repair using epoxy
#56: alloy body nailed to framing
#28 (p. 27-28): engine compartment looking fwd and backwards
#46 (p. 47-48): rear framing & B pillars
#52 (p. 50-52): frame and rockers
#55 (p. 53-58): rear framing
#57 (p. 59): front framing
#57: frame rust prevention
#59: looking back at rear frame from between doors
#62 (p. 63-66): rear frame and differential mounts
#112-113: determining strength of main frame tubes
#181 (p. 261-267): borescope examination of inside frame tubes and discussion of strengthening needs
#182-185: frame strength discussions
#197-202 (p. 288-309): frame strength analysis and reinforcing tube insertion
#199: old reinforcement tube for differential mounts
#203: front subframe
#204-205 (p. 318-321): closing frame holes
#206-207 (p. 322-325): rocker repairs
#208: upper rear shock mounts
#211-213 (p. 334-338): rear frame repairs and how to do them
#208 (p. 326-331): rear frame (behind seats) repairs
#217 (p. 347-348): bracket for spare wheel fixing rod
#221: alignment discussion
#222: closing main frame tubes
#222-224: sill frame reconstruction
#225 (p.366-369): frame repairs behind seats
#226 (p. 370): seat runner supports
#226 (p. 370-372): B column brace
#227: rear subframe
#218 (p. 349): rear subframe complete
#227 (p. 372-374): rear subframe installation
#293: brackets to attached panel behind seats
#315: door jamb A pillar panels
#316: right side rocker repairs
#317: front frame exposed
#319: rebuilding front frame
#327: framing reconstruction at bottom of A pillars
#333: door jamb A pillar panels
#334: JOKE about stripped frame
#335: painted frame
#336-337: frame coating
#367: rear bulkhead and framing
Fuel Pump
#374: installation and mounting
#392: mounts and fuel filter
#396-397: fuel pump plumbing
Fuel Tank
#25 (p. 22): fuel tank mounting and rear frame
#36 (p. 36): fuel tank internal plumbing
#219: interference with A arm brackets
#219-221 (p. 350): fitting fuel tank, repairing frame to suit.
#246 (p. 404-405): fuel tank straps
#294: installed
#322: modifying fuel tank for Zephyr
#390: fuel tank construction and testing
#392: fuel level sender and fuel line
#392: old and new tanks compared
#392: fuel filler cover
#393-394: fuel tank construction
Gearbox and Clutch
#12: Ford 289 V8 and toploader
#96: toploader in car
#120: gearbox with drive shaft
#120: half shafts
#122: gearbox bracket
#133: gearbox etc in car
#295: Zephyr gearbox
#299: Ford Type 9 gearbox
#299: clutch and flywheel
#300: Zephyr and gearbox
#300: fitting gearbox to frame and footboxes
#309: bell housing for Ford Type 9
#363: clutch hydraulic lines
#378-379: gearbox shortening
#380: shift lever and knob
#385: gearbox fitting comments
#387: right angle speedometer drive construction
Grease Gun
#279: R&R
#403: grease gun mounts
Hatch
#127: as bought
#128 (p. 158): hatch
#248-249 (p. 410-414): hatch window and fitting
#252-253 (p. 423-429): hatch R&R
#253: hatch lock mount
#368: hatch installation and shimming
#403: handle, latch, and badge
#412: struts and modifications
#417: leather work on hatch window edge
#417: hatch mounting and hinges
Headers
For 289
#127: header on motor
#133: new headers
#133: mounting motor with headers
#134: header problem with motor mount
#157 (p. 216-220): making headers
For Zephyr
#326: header construction
Heater & Ventilation
#69 (p. 70-71): MGA heater and duct
#129 (p. 164): heater vents
#172 (p. 252-253): foot box air vents
#186: ducts
#323: original heating system ducts
#324: heater fitting and mounts (for Zephyr)
#324: ducts
#328: heater ducts and addition of heater ducts to Smiths heater
#365: heater, heater ducts and vents
#366: demister and heater installations
#371, 411: heater and heater hoses installed
#374: R side heater and vent hose arrangement, mounting bracket
#402: ventilation hoses and mounts
#411: heater valve, mounts, and associated hoses
Project History
#400-401: progress
Horns
#89 (p. 97): horns
#368: horn switch
Hubs
#344: front and rear axle disassembly
#345: rear hub problems
#348: hubs, spindles, and uprights back from painter
Lights
#37: tail lights
#358: headlight alignment
#423: driving lights
Instruments
#7: speedometer drive
#60-61: speedometer cable discussion
#125: speedometer cable discussion
#142-145: speedometer and tachometer mounting in binnacle
#384: instrument panel construction
#412: speedometer cable fabrication and connection
#418-421: Lambda sensor, air/fuel monitor
Motors
#12 (p. 13/455): Ford 289 and toploader
#28: 289 vs Daimler V8
#29-31: comparing motor weights
Carburetor
#124: converting Holley Street Avenger to manual choke
Zephyr
#295: Ford Zephyr Mk II motor and gearbox
#295: stripping block
#296: stripping head
#297: flywheel, friction plate, clutch cover
#300: Zephyr motor and gearbox much longer and narrower than 289 and toploader
#300-302: fitting Zephyr in car
#306: Zephyr connecting rods
#307: valve gear, water pump, oil filter
#308: assembling intake and carburetors
#308: fitting in car
#311: distributor and ignition system
#312: accessory brackets, oil pan, oil temp sensor, engine mounts, drive shaft
#312: starter
#371: motor installed
#376: increased displacement possibilities
#382-383: flywheel cover, crankshaft
Motor and Gearbox Mounts
#94 (p. 105-110): mounting 289 and toploader
#97 (p. 113-119): engine mounts
#120: motor mount
#133 (p. 169-170): frame modifications to fit motor and gearbox
#133: mounting motor and transmission in car
#134 (p. 172-173): motor mounts
#178 (p. 254-255): transverse brace for preventing engine mount rotation (note that mounts are clamped, not welded, to the frame to make motor change possible)
#194 (p. 281-286): improved engine mounts
#202-204 (p. 312-317): another improved engine mount to brace frame alignment
#228-229 (p. 375-380): improved engine mounts
#229-230: drive shaft safety loop
#309: Ford Type 9 gearbox fitting
#384: gearbox fitting and mounting
#398: motor installation
#398: engine mounts and modifications
Radiator
#28: radiator and fan
#314: radiator
#407: dimple dies
#407-410: expansion tank mounting and discussion
Cooling Fan
#314: cooling fan
Replating
#151-152 various parts before and after
Reservoirs
#132 (p. 167): clutch and brake fluid reservoirs
#403: clutch and brake reservoirs mounted

... to continue ...

What do I do with the Aceca? Well, I try to get it on the road. For that I had a lot of small jobs. Today, I installed a hazard switch. Not so easy to detect the right wires for the brake light switch and the flasher can in an unknown wire loom. Both must be disconnected from the ignition and must be connected to the hazyrd switch so that in the case of switched on ignition, switched on hazard switch and pushing the brake the hazard switch has the highest priority.

dkp_cobra · August 09, 2011, 11:29:15

RESTORATION OF BE646 2011 - TO DATE (23 May 2023/MSG 412)

SUBJECT INDEX

PART 2/2

Steering
#98-100 (p. 119-123): steering gear
#102-107: rack and pinion conversion discussion
#109 (p. 125): rack and pinion mountings
#119: steering
#123: steering rack placement
#114-118: steering discussions
#118 (p. 130-140): steering discussion and x-ray
#120: steering shaft mount
#135 (p. 176-177): steering shaft location
#172: steering column mounting bracket
#178: steering shaft mounting
#186: upper steering column bracket
#363: steering column
#370: steering column rebuild and installation
#374: steering wheel and hub
Suspension
#187 (p. 271-273): removing running gear/A arms (wishbones)/suspension
#208: upper rear shock mounts
#216 (p. 342-345): shock absorber bracket repairs & others
#216: right rear lower A-arm bracket repairs
#219: right rear lower A-arm bracket repairs
#220: front lower A-arm brackets and repairs
#219-221 (p. 350): discussion of A-arm bracket alignment misalignment etc
#250 (p. 415-419): rear right lower A-arm bracket repair and modification
#250: front A-arm stiffening
#251: finished rear A-arms
#333: addition of front leaf spring leaves
#338: rear spring, modified front spring
#338: new front spring mounting brackets
#338: reassembly of front and rear springs
#377: damper specifications
#377: front and rear hubs, drive shafts, axles, and steering
#404-406: suspension spring wrapping
Washer:
#96: wheelbox R&R
#403: wash bottle and mounts
Weights
#30-31: motor and gearbox weights
Wheels
#51: wheel specifications
#339: wheel specifications
Wiper
#70 (p. 72-73): wiper wiring
#74, 77 (p. 76-81): windshield wiper motor and mechanism
#374: rebuild and installation, including mounting bracket
Zephyr:
#295: motor and gearbox
#296: motor
#299: clutch and flywheel
#300: motor and gearbox
#300: motor vs 289
#300: motor and gearbox in car
#300: new transmission tunnel
#309: bell housing for Ford Type 9 gearbox
#312: in car

If you ever wanted to know what's inside of an Aceca door, it's wood:

And if you have used your car in rain during the last 50 years, it's dilapidated wood:

That gives the door some kind of flexibility [xx(]

Gus Meyjes · August 09, 2011, 13:54:16

wow,

   I was lucky I still had good wood...[;)]

   That will need the skills of a good cabinet maker in order to get the curves just right!

   Gus

AEX566 · August 10, 2011, 00:07:07

As the door frame's not cosmetic wood, you might consider using the marine repair system for rotted wood: small holes are drilled in from above, then special thin penetrating epoxy that seeps into the wood is injected down filling holes using a syringe. This solution results in a solid, strong section. Beyond boat repair, this is often used for architectural restoration of bad windowsills and frames. You'd save unwrapping the aluminum door skin at the bottom, and the result is as strong if not stronger than the original ash. Finish up by coating and sealing all the inside door wood with epoxy so moisture can't penetrate. Check boat repair vendors for correct epoxy; in the US one brand is Git-Rot. There are a number of You Tube videos to watch as well.
If the door has sagged on the rear lower corner as the screws have loosened in the bad wood, use a Spanish windless to realign and then renew the corner ply. Of course if all the wood in the door is bad, go for the cabinet maker.
Art

dkp_cobra · August 11, 2011, 14:32:58

quote:
Originally posted by AEX566

As the door frame's not cosmetic wood, you might consider using the marine repair system for rotted wood: small holes are drilled in from above, then special thin penetrating epoxy that seeps into the wood is injected down filling holes using a syringe. This solution results in a solid, strong section. Beyond boat repair, this is often used for architectural restoration of bad windowsills and frames. You'd save unwrapping the aluminum door skin at the bottom, and the result is as strong if not stronger than the original ash. Finish up by coating and sealing all the inside door wood with epoxy so moisture can't penetrate. Check boat repair vendors for correct epoxy; in the US one brand is Git-Rot. There are a number of You Tube videos to watch as well.
   If the door has sagged on the rear lower corner as the screws have loosened in the bad wood, use a Spanish windless to realign and then renew the corner ply. Of course if all the wood in the door is bad, go for the cabinet maker.
   Art

   Art,

   thank you for your advice. When the time has come to make the doors I will check the possibility. Currently, I am working on small items in order to get the car on the road.

   Regards,

   Peter

dkp_cobra · August 11, 2011, 14:39:39

I think I know why the speedometer doesn't work. Maybe it's this strange looking elbow gear at the transmission:

This should work better:

   Now, I have two questions:

   1) is it normal that the hand brake lever is not covered:

   2) Is this the normal transmission of an Aceca or something else:

Robin A Woolmer · August 11, 2011, 16:20:01

Handbrake looks none standard & the Moss Box appears from a Jag MK2 but i am not an Aceca Specialist.
Robin

dkp_cobra · August 11, 2011, 16:31:02

quote:
Originally posted by Robin A Woolmer

Handbrake looks none standard & the Moss Box appears from a Jag MK2 but i am not an Aceca Specialist.
   Robin

The engine is a Daimler 2.5 V8. This may fit the Jag MK2 Moss Box.

bex316 · August 12, 2011, 01:05:18

The handbrake lever and its operating mechanism look standard Ace/Aceca to me but the tower on which it is mounted does not look familiar to me.
   The operating mechanism should be covered with a piece of carpet, actually consisting of 3 pieces sewn together (upper part and 2 sides). The upper part should have an opening at the front through which the lever can slide up and down.

   Jerry

dkp_cobra · August 12, 2011, 16:08:22

quote:
Originally posted by bex316

The handbrake lever and its operating mechanism look standard Ace/Aceca to me but the tower on which it is mounted does not look familiar to me.
   The operating mechanism should be covered with a piece of carpet, actually consisting of 3 pieces sewn together (upper part and 2 sides). The upper part should have an opening at the front through which the lever can slide up and down.

   Jerry

   Jerry,

   please, can you send me a picture of this cover?

   Peter

dkp_cobra · August 25, 2011, 09:39:03

Yes, it's a shame but this will be the new drive-train:

A 1964 289 cid Ford with a top-loader.

Gus Meyjes · August 25, 2011, 15:48:30

not a shame if you did not have the original motor anyway... be sure to beef up the rest of the drive train.

Gus

dkp_cobra · August 25, 2011, 16:05:35

quote:
Originally posted by Gus Meyjes

not a shame if you did not have the original motor anyway... be sure to beef up the rest of the drive train.

   Gus

I plan to use a Jag diff. and there are some drive shafts from my MK IV laying around [:)]

AC Owners Club Forum

News:

BE 646

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Gus Meyjes

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Gus Meyjes

AEX566

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Robin A Woolmer

dkp_cobra

bex316

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Gus Meyjes

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