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The
budget was tight so no acid dipping here. Take one £50 sunbeam
and 40kg of kiln dried sand, result? one bare metal teabag! |

The
turrets were braced with Gartrac Escort strut-top plates. The inner
wings had to be made up as well due to excessive corrosion. |
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The
front tie-bar mounts were braced to the front panel prior to shot-blasting |

As
the car was seam-welded & braced either stone chip or primer was
used to protect the shell prior to paint. |
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The
rear chassis legs were virtually rebuilt from scatch. Note the
pop-riveted rear 1/4 repair! |

The
rear arches were cut out and filled with sheet steel to prevent
wider tyres fouling the bodywork |
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MK1
Fiesta lower 1/4 panels were used to repair the Sunbeam. When
cleaned up you can't tell they aren't original! |

Its
hard to see here but every single seam on this shell has been
stitched welded. It took ages to do but the shell feels 100% stiffer
than our first car. |
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The
metal in so many areas on the shell was paper thin. The only was to
repair them was to cut out the poor steel in sections. |

Just
before paint. You can see the 'arched' rear quarters and opened out
valance. Also note the hole behind the number plate. If it's not
doing anything why not cut it out? |
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Bless!
The old shell as it's stripped prior to selling. Can anyone tell me
what the front panel came from? |

6:30pm
Friday evening & the shell is being wrapped in tarpaulin to
prevent moisture damage prior to paint. |
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8:30am
Sunday morning and the shell is returned freshly painted after a
night in the oven. Thanks Ian! |

The
prototype Sunbeam roof vent after paint. A perfect fit! |
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Assembly
of the interior is well underway. note the clocks are mounted into
Twin-Tek (space age stuff!) and the flocked dashboard.
Simply-Sunbeams can Flock your dash for you. |

Willwood
Dynalite calipers. Flipping Stupendous! The pads we use are secret
(We can out-brake Imprezas with these fitted!) |
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Did
you know Escort roller top mounts fit a Sunbeam? Well you do now. |

The
engine wasn't touched but a new gearbox was built with better
gearing to cope with hairpins & runways used on single-venue
stage rallies. |
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We'd
cut so much weight out of the new shell that the rear of the car sat
40mm higher on the same springs. Testament to now much effort was
placed on removing un-necessary weight. Shame about the fat driver then! |

Almost
finished and ready for graphics. Diluted Fairy Liquid & a credit
card wrapped in kitchen roll can give you a professional finish to
your stickers.
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One
completed Rally car, Fresh from a class win on her first event!
Proof
that Prior Preparation Prevents Piss-Poor Performance!
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