Magazine – The Surgery – Classic Car Restoration Wellington https://www.thesurgery.co.nz The Surgery restore and repair classic and collectible cars Wed, 20 Aug 2025 23:55:43 +0000 en-US hourly 1 https://wordpress.org/?v=6.8.2 1966 Ford Mustang in New Zealand Classic Car https://www.thesurgery.co.nz/services/restoration/1966-ford-mustang-in-new-zealand-classic-car/ https://www.thesurgery.co.nz/services/restoration/1966-ford-mustang-in-new-zealand-classic-car/#respond Wed, 20 Aug 2025 00:30:00 +0000 https://www.thesurgery.co.nz/?p=7085 So cool to see Gordie’s beautiful 1966 Ford Mustang that we worked on featured in the latest New Zealand Classic Car Magazine.

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ID Buzz & KEV The EV Kombi https://www.thesurgery.co.nz/services/restoration/id-buzz-kev-the-ev-kombi/ https://www.thesurgery.co.nz/services/restoration/id-buzz-kev-the-ev-kombi/#respond Fri, 08 Aug 2025 22:30:00 +0000 https://www.thesurgery.co.nz/?p=7068 With the launch of Volkswagens new ID buzz featured in this month’s New Zealand AutoCar magazine. Kev, the Kombi, was also featured right beside it. This 1966 classic was brought back to life by our team at The Surgery and converted to electric in an old meets new tribute to a true icon

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His and Her Thunderbirds https://www.thesurgery.co.nz/manufacturers/ford/his-and-her-thunderbirds/ https://www.thesurgery.co.nz/manufacturers/ford/his-and-her-thunderbirds/#respond Tue, 29 Apr 2025 02:21:00 +0000 https://www.thesurgery.co.nz/?p=6385 Two of our clients have featured in this month’s New Zealand Classic Car magazine, with his and her Thunderbirds. A nice collection they have, grab a copy and have a read

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Peace, Love and Energy – KEV The Kombi Electric Vehicle https://www.thesurgery.co.nz/featured-projects/peace-love-and-energy-kev-the-kombi-electric-vehicle/ https://www.thesurgery.co.nz/featured-projects/peace-love-and-energy-kev-the-kombi-electric-vehicle/#comments Wed, 24 Jan 2024 00:17:29 +0000 https://www.thesurgery.co.nz/?p=5618 Volkswagen revolutionised the transport world, not just once with the launch of the people’s car, the Beetle, but a second time around with the Type 2. Initially launched in 1950, the Type 2, more commonly known in this part of the world as the Kombi, took the concept of a forward control vehicle and made it affordable for the masses. The design and price weren’t the only success stories for Volkswagen though, the marketing was a hit too.

It was likely a combination, or perhaps a kombi-nation, of these three things that set the Kombi on a path to becoming the global automotive icon it is today. It was so successful that production continued in various forms right up until 1975. In today’s world where manufacturers run models
for an average of six years before re-tooling, a 25-year production run is almost incomprehensible. That run was no doubt in part due to the vehicle’s popularity which ramped up throughout the late 1950s and early 1960s.

The hippy movement was closely aligned with the Kombi thanks to their easy to work on design, low
cost, and people-carrying capability. So aligned were the Kombi and the peace, love, and freedom movement, that the vehicles became a symbol of the time. That symbolism continues today where it’s not uncommon to see a peace sign, flowers, or other similar iconography on Kombis around the

globe. Even Volkswagen New Zealand are in on the act, coming up with the concept of highlighting the Kombi’s carefree roots to help market the recently released successor, the VW IDBuzz.

The IDBuzz has all the hallmarks of the Kombi, including a unique design, great engineering, a focus on working to suit any lifestyle choice, and of course great marketing to match. The IDBuzz is also VW’s first foray into an all-electric van, and while it’s far from VW’s first electric vehicle, it may soon become their most popular.

KIWI KOMBI

To coincide with the local launch of the IDBuzz, Volkswagen New Zealand decided to play on the Kombi’s long and successful history by creating a unique Kombi of its own. The plan was to craft a vehicle that embodied the spirit of the original vehicles but with a modern twist to show how far the company has come, and to encourage fellow VW owners to do the same. The big twist – pun intended – is an electric motor powerplant, and VW would open-source the method of the steps required.

In VW’s words: “From the moment it was born, the Kombi has been a symbol of hope for a better world. Now, 65 years later, leaving the world

a better place for future generations is more important than ever. That’s why Volkswagen is making a shift to a more sustainable future by starting our journey into electric vehicles. And what better way to hit the road on our journey than by bringing back an icon from the past, so it can lead us into the future.”

For this epic transformation, they enlisted the help of one of the country’s foremost restoration shops, which also happens to be the business that has likely converted more classics to electric power than any other, Wellington’s

The Surgery. Business owner John Stevenson-Galvin states that there was no plan for the business to become classic EV specialists; the business simply evolved with the times and in the direction customers wanted.

Of course, the advantage for the customers, VW NZ included, is that The Surgery can take care of full builds like this in house, rather than just the engine side or the panel restoration aspects of car building/ restoration. With a deadline of just 12 months away, the build was a big ask, but John and the team at The Surgery are no strangers to pressure, and thankfully their years of experience and robust processes helped to make the seemingly impossible, possible.

RARE OPPORTUNITY

The 1960 Kombi they started with is remarkably rare, being just one of 500 made with both a split screen and a sliding door, which adds weight to the story that it started life as an ambulance. In the years since being on duty the vehicle has changed hands a few times, as well as the subject of a left-hand drive to right-hand drive standard dash configuration except for the battery level indicator conversion.

Of course, the conversion wasn’t up to the standard required by VW NZ nor the standard that would be let out of The Surgery’s doors. The starting point for the build was stripping it down to a shell before rolling it next door to Metal Immersions to be dipped. This exposed the usual rust expected in a vehicle of this age, as well as a few unexpected repairs from days gone by.

Masters at their trade, repairing this sort of stuff is bread and butter work for The Surgery’s team, and having worked on countless Kombis before, they knew exactly what was required. While this was being undertaken, a comprehensive parts list was being put together, much of which was sourced through VW specialist parts supplier The Metric Nut.

“There’s a huge culture and aftermarket parts network for these things now, but there’s also a lot of poor-quality parts out there,” says John.

“From our own experience, and through working with The Metric Nut, we know exactly what works and what doesn’t.”

Getting things to production car build standards is one of the things that sets businesses like The Surgery apart from most home builds, and for a car that will be driven by countless people – many with no old car experience – that was even more important in this instance.

Helping with that drivability is a narrowed front end that has been rebuilt with all new bushes seals and bearings, while the old drum brakes have been replaced with a Metric Nut disc brake conversion setup. One requirement of the electric powertrain conversion was an aftermarket electric brake booster to compensate for the electric motor’s absence of vacuum. Of course, the big talking point

is the EV conversion, and while that too aids with drivability, that wasn’t the main driver. Having converted a number of other VWs to EVs, the team knew what components were required, the main one being a Net Gain HyPer 9 motor that produces 112kW peak power and 235Nm. That’s plenty of performance in a lightweight Kombi and, thanks to the torque being the same from zero RPM, the van is easy to drive.

With that torque, there’s no need for the gearbox but, as John pointed out, keeping it also makes sense as the engine installation is simplified.

It also allows for reverse to still be used without the addition of any complex electronic controllers. To enable this, the shifter mechanism of the box has been modified to lock out all gears besides third and reverse and, handily, the original speedo drive is still in place to twist the speedometer.

RECHARGING AND RECYCLING

Throughout the build, VW NZ was keen to reuse what wasn’t broken, both the original components of the vehicle, and whatever else they had available, which in this case were batteries. Rather than purchase new batteries, they used a number of 1.6kWh/108AH battery modules traditionally found in the company’s e-Golf models. Eight of these are in the position of the standard fuel tank, while eight more sit beneath the centre of the vehicle between the chassis rails. Although there’s no official measurement on the vehicle’s range, John estimates it to be between 150 to 200km, which is more than most classics will generally travel between stops.

As the build came together the team enlisted the services of Kerry’s Upholstery for the soft furnishings. That included trimming the custom L-shaped rear seating arrangement that had been fabricated in-house along with the original but refurbished front seats. The remainder of the interior looks as if the car just rolled off the production line in 1960, which was all part of the plan. The exterior is pure Kombi too; the hippy-inspired artwork adorning the sides of it is a clever mix of retro-modernism, complete with plenty of subtle details hinting at what lies within.

The engine bay also looks like it could have been created at the factory, such is the attention to
detail. It includes a custom plate to seal off the electric motor from the undercarriage. It’s details such as this that elevate the build far beyond what an off-the-shelf conversion kit could offer. John has well-earned scepticism about conversions sold as bolt-in. In reality, they have only a fraction of the components required, and none of the expertise. If you’re thinking that performing an EV conversion is a great way to save money, he cautions you’ll be very mistaken.

The cheapest way into an EV is to buy a production vehicle, but a conversion such as this is a great way to get another classic back on the road and have some fun in the process. Don’t get sucked into all the misinformation about batteries killing the world or bursting into flames all the time and you’ll have every bit as much fun as the drivers of combustion engined vehicles, if not more. Instant torque and zero maintenance are just two of the selling points for a vehicle that costs next to nothing to run, and produces no harmful emissions in the process.

VW NZ successfully unveiled the Kombi, celebrating both its revered history and continued relevance
on their stand at National Fieldays earlier this year, where it was met with much applause. Understandably the certification process for a conversion like this is thorough, but that’s nothing that the team haven’t been through before, and there’s never any question about The Surgery’s workmanship.

Driving the car is every bit as much fun as it looks promise. No wide-gated offset gears to grind through, no carbs to tune or points to change, just jump in, push the start button, and go. Just like the original marketing when the Kombi was launched in 1960, this rolling publicity stunt has been a huge hit, showcasing the vehicle’s versatility to a whole new generation of fans. Except this time around, it’s not about flower power, but battery power.

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Forever Young – VW Kombi https://www.thesurgery.co.nz/photography/forever-young/ https://www.thesurgery.co.nz/photography/forever-young/#respond Tue, 06 Jul 2021 09:51:08 +0000 https://www.thesurgery.co.nz/?p=4504 The VW Kombi van is one of the best-known vehicles in automotive history, and for owners such as Steve and Denise Fejos, this loyal steed helps make memories that will never be forgotten

Dutch Volkswagen importer Ben Pon visited the VW factory on Wednesday, 23 April 1947, when it was still controlled by the British Occupational Forces under the command of Major Ivan Hirst, a British Army officer and engineer assigned to rebuild Volkswagen after the war. Pon wanted to talk about importing Volkswagens into the Netherlands, but it was a special day because he did something else. He took out his notebook and drew an oblong transport vehicle. It was basically no more than a soapbox on wheels, with the cab in front, and in the back, the engine.

How his conversation ended, nobody knows. But one thing is for sure, in 1947 his idea was revolutionary. It was brilliantly simple a large cargo space in a small area. According to Pon’s calculations, the vehicle would weigh in at just 750 kilos and be capable of carrying cargo in excess of 750 kilos as well. He based his design on the Plattenwagen, a primitive vehicle which looks like a pushbike with a moped engine, designed by the Volkswagen engineers for internal factory transportation at the Volkswagen plant. Like the Plattenwagen, his design had to be built on the chassis of a Beetle.

SPLITTY
The first generation of Volkswagen buses, the Type 2 — often referred to as split-window buses, the split-screen,microbus, or the ‘Splitty’ — were built between 1949 and 1967. This second vehicle line introduced by Volkswagen, after the iconic Beetle, is generally considered to be the forerunner of modern van. Split-screen vans came in many guises, as a panel, kombi, standard, deluxe, ambulance, fire truck, single and double cab, walk-through, and double door versions, during an 18-year production period. Split-screen models are recognisable for the sweeping V-line front and a large VW emblem. They also boasted generous interior space, about 4.8 cubic metres, which made them ideal for tradespeople and for carrying passengers.

The engine was courtesy of the Beetle, but the Splitty boasted unitary construction supported by a ladder frame. It consisted of two longitudinal parallel girders or beams upon which the suspension, engine, and transmission are mounted, instead of on the central frame platform. The payload was roughly 750kg, and the torsional rigidity inherent in the design ensures that the handling, although not brilliant, is adequate, which explains their usefulness as transporters. The engine had a cubic capacity of just over 1100cc, with an output of 18kW at 3300rpm.

Five decades on, this old-school icon from the 1960s — the era of the Beatles, Woodstock, love, peace, and all things free — built its own sub-culture associated with road trips, surfing, safaris, and endless summer. Given those associations with youth and innocence, the hippiemobile, hippie bus, hippie van, call it what you will, is as popular as ever, whether you actually experienced that kind of carefree VW- powered wandering back then or not. This friendly and fun-loving van with its bubbly engine note bustles its way into everyone’s affections with as much personality as a floppy family dog.

While the second-generation models are almost as revered, the original Splitties are now rare and highly prized collector’s items all over the globe. Whatever nickname you give it, the Kombi reigns supreme over its segment and has set itself into history for good.

KOMBINED HOLIDAYS
We recently caught up with VW enthusiast Steve Fejos, son of Hungarian parents who arrived in New Zealand as refugees after the ’56 uprising. Being European, Steve was naturally attracted to European cars, especially the more affordable VWs. “We must have owned at least 20 Kombis and Beetles over the years,” says Steve. “My father was a handyman and was always doing things buying, selling, and doing work and repairs at his property, so the Kombi was the ideal workhorse he needed.” As a young boy, under 10 years of age, Steve always liked to tag along with his father. Kombis in the 1960s and 1970s were usually rust buckets, but that didn’t deter his father from buying one every year and spending the winter months ‘doing it up’. “My father’s method of restoration usually included a few tin sheets, plenty of body filler, and a quick coat of paint, done in the driveway, ready for the family Christmas adventure to Taupo, Rotorua, and Auckland, departing every year on Boxing Day,” says Steve.

These definitely were far more basic than salubrious campers with all modcons you see travelling the country today. Many had nothing more than mattress tightly squeezed onto a home-built base as the family explored various camp sites around the North Island. Upon their return home, the Kombi was sold, and each year the process began again. “I have incredibly fond memories of working with my dad. We learnt everything about Kombis and the motors. We could pull out a motor in 30 minutes as teenagers, plus we naturally had all the gear and specialised tools, not that there was much needed,” says Steve.

THE ONE
Steve has dreamt of owning his own classic Kombi, but for many years it was never the right time or not the right van. Steve instantly knew he’d found the right Kombi when he discovered this much-loved example in Gisborne. It had been owned by the same couple for almost 40 years. They also had an album full of lasting memories of many years of camping holidays with their kids. The Kombi also came with an added bonus, which clinched the deal for Steve. It was not only the last German-assembled, right-hand drive, split-window built-in 1967, but it was also a rare factory ‘walk through’. These models had a single passenger and driver seat, allowing you to walk through to the rear.

With the deal done, Steve was excited to pick up his new pride and joy the following morning. “As I hit the motorway, it blew a spark plug — it had de-threaded. I had never seen or heard of that happening before. I limped the van to Thorndon. I had to have it trucked home to Johnsonville — to be greeted with applause by my neighbours and friends,” says Steve.

Steve would like to say a special thanks to the team at The Surgery, including Maurice Lindsay, the mechanic responsible for the engine work, and Lance Parker of Rotary Motor Trimmers who made six attempts at fitting the ceiling until it was perfect. He also imported the material for the seat cushions from Australia to have it as close to the original cushions as possible and replaced with the piping, etc, to have the absolute original look.

SURGICAL PROCEDURE
The first call Steve made was to renowned restoration specialist John Galvin at The Surgery. “I was so pleased we have such expertise based here in Wellington,” says Steve. Within a couple of weeks, it was another trip on the back of a tow truck to The Surgery for an analysis. “With the expertise on hand from the team at The Surgery we made some very logical decisions to ensure we had a reliable vehicle. We ended up fitting a complete new 1500cc motor built to original specifications.” This wasn’t exactly spoiling its originality, as the original motor had been changed out 25 years ago. The only upgrade was electronic ignition and a stainless steel exhaust. The gearbox had a whine, so that too was completely rebuilt to original specifications. While the running gear was out, the petrol tank was also removed, flushed, and repainted in original colours, and the motor housing area was sandblasted and repainted. Everything mechanical was restored and reconditioned. The original kingpins that were also replaced, and a reconditioned steering box fitted.

“Where possible, everything has been kept original and the temptation to modernise resisted. We even still have the drum brakes, which work absolutely fine,” says Steve. He had wanted to repaint the Kombi red and white, but a work progressed he realised this was perhaps the most original Kombi still running and thought a colour change back to its original Velvet Green and Pearl White scheme was more appropriate. All the brightwork was refurbished, plus a few modern chrome accessories were ordered and fitted. “The van has always been registered and has retained the original black plates, which to me added value and originality,” says Steve.


The van retains the original badges, cabinets, and hinges, and it even has the original clothes hangers for the wardrobe, which are held in place with the original wooden dowels. Steve repaired and restored the cabinetry (during lockdown). The ceiling has been relined in new, original-style VW material, and the upholstery fabric for
the seats was imported from Australia. “We have endeavoured to add some modern luxuries to the camping
experience, including a drive-in tent with fully closable sides — we do have the original awning but prefer the much larger option — and our camping table comes complete with our Nespresso machine. The original gas stove still works and is intact and even came with the original refillable gas bottle,” says Steve.

Now as a grandparent — and as a tribute to his late father — Steve and his wife Denise are now sharing that same camping experience with their grandkids for a Kombined experience.

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1977 Toyota FJ40 Land Cruiser – Surgical Procedure https://www.thesurgery.co.nz/photography/1977-toyota-fj40-land-cruiser-surgical-procedure/ https://www.thesurgery.co.nz/photography/1977-toyota-fj40-land-cruiser-surgical-procedure/#comments Sat, 22 Jul 2017 00:00:20 +0000 https://www.thesurgery.co.nz/?p=2432

The road into this story is a long and winding one, which begins when three of the Muir brothers — Tony, Neville, and Guy — began developing a 121-lot subdivision in Ngaio, Wellington, in 1970. Tony initially owned a 1965 Land Rover, and, in 1968, he and Guy purchased two new Austin Gipsys, originally designed as competitors to the Landy. In 1976, the brothers replaced the Gipsys with two new Toyota Land Cruisers (these days referred to as ‘FJ40s’), and, in 1978, the three brothers formed a new company, Ridvan Garden Developments Ltd.
The Toyota FJ40s proved to be the most reliable, capable, and tough vehicles the brothers had ever owned, and they kept them for more than 20 years. Both families traveled all over New Zealand towing caravans, driving thousands of kilometers, getting off-road whenever they could, and generally using the vehicles as they were intended, long before the days of mainstream SUVs.

It’s hardly surprising they were so impressed, given that the Toyota FJ40 Land Cruiser is possibly one of the best off-road vehicles ever produced, and arguably stands alone as the most reliable, long-lasting, and virtually unbreakable vehicle, one which can get you anywhere you need to be. This sturdy machine has an enviable reputation for needing little-to-no modification straight out of the factory, as its stock four-wheel drive is capable of overcoming just about any obstacle in its path. Even today, FJ40s can be found just about anywhere in the world with several hundred thousand kilometres and the stock engine still running strong.

Throughout the ’70s and ’80s, Tony and Guy were heavily involved as volunteers in Civil Defence. Tony was a warden for One Mike (the Ngaio area) and, later, northern suburb controller at Sub-Area One. On a number of occasions, Tony organized Civil Defence exercises and demonstrations at school fairs and Wahine commemorations, as well as emergency-services training exercises at which both Cruisers were front and centre, kitted out with sirens and beacons. And when a civil emergency was declared during the floods of December 1976, the FJ40s were put to work doing what they do best.

Tony’s son Doug purchased a 1981 BJ40 (the diesel version of the FJ40) in 1990, and used it as his daily runabout for more than 15 years.

The vehicles proved their worth time and again, but, unfortunately, their only flaw — their tendency to rust — reared its ugly head, so, after many years, this issue meant that the Land Cruisers were eventually all sold.

Guy and Neville had retired in the early ’80s; Tony and Judy had become sole owners of the company; and, eventually, they employed their sons — Ant and Doug — and their nephew, Gary. Ridvan Garden Developments began developing a new 78-lot subdivision in Crofton Downs, Wellington, in 1999. The terrain was rugged farmland, and they needed a vehicle to get down into the deepest, darkest gullies on the Downing Street property. As luck would have it, one of the earthworks operators was selling his 1977 FJ40.

It was a no-brainer — Ridvan purchased the truck. Once it had been changed to run mud tyres and the front passenger and rear seats had been pulled out, leaving only the driver seat (so more gear could be loaded), the vehicle was put to work loading and moving pipes, cement, mortar, tools, and even drainage metal all over the subdivision. It was a demanding role, but the FJ40 was more than adequate for the task. Diggers would make a rough track through the bush, and, loaded with materials and equipment, the FJ40 would be driven down into the gullies to start sub-soils and drains.

The years passed and the FJ40 never missed a beat, starting first time every time, a testament to the Japanese approach to engineering that rested entirely on the relentless  pursuit of perfection. It was never an option to adopt the philosophy of ‘If it ain’t broke, don’t fix it’, as the company would prefer that it never broke at all. After all, why replace something when you can build it right the first time? This is undoubtedly why the quality and durability of the FJ’s transmission and suspension are legendary. Take the leaf-spring suspension, for example — it’s absolutely suited for a heavy vehicle like the FJ, spreading the weight around evenly; plus, it actually obviates the need for additional weight from the extra parts that you would need with coil suspension.

Sadly, after receiving as much punishment as Ridvan’s harshest drivers could throw at it, the bodywork had taken a pounding and rust had set in.

Then, tragedy — parked on a vacant section surrounded by finished and half-built houses, the FJ was stolen. Police were informed but advised that the chances of recovery were virtually nil.

However, on Father’s Day 2009, a friend was at his local church when he looked over the fence into the neighbour’s property and saw, partially hidden under an old tarpaulin, an FJ40. After looking at it a little more closely, he rang Doug, who went around to the church and verified it was Ridvan Garden Developments’ missing Cruiser. Police were told, and the vehicle was recovered and started first time once a new battery had been installed. The stolen vehicle had been driven from Crofton Downs to Titahi Bay. For two years, it had been parked under a tarpaulin just 800m, as the crow flies, from Doug’s back door.

With earthworks on the subdivision completed, the vehicle was no longer required for its workhorse capabilities, so the decision was made to restore the FJ40 to its former glory. Doug sourced body panels and many other parts from all over New Zealand and overseas, often dropping in on a Sunday evening to show Tony and Judy his latest find. Finally, all the parts were located, and the skilled team at The Surgery in Tawa went to work.

The team at The Surgery knew right from the start of the project that the FJ40 was something very special to Doug and the rest of the Muir family. It may have been just an FJ40 to most people, but, to the Muirs, it may as well have been an F40!

The initial brief from Doug was, “Can you bring her back from the dead and make her like a brand-new vehicle, or better?”
The answer from The Surgery was a definite, “Yes —we would love to take up that challenge.”

When the Land Cruiser initially arrived at The Surgery, it was in an extremely sad and rusted state — some would have called it a basket case. Every panel, including the chassis, had severe rust, so the decision was made to completely disassemble the FJ40 down to every last nut and bolt, and then completely acid-dip strip all the body and loose panels back to bare steel. Very early in the project, they discovered that there were very few new steel panels available for the many rust repairs needed, so the mission was to fabricate 99 per cent of all the new panels required for the restoration.

While the body stripping was underway, the engine, driveline, suspension, and brakes were removed from chassis. The engine and transmission, clutch and differential were completely stripped and reconditioned, while the entire braking system received a complete overhaul that included all new parts, master cylinder, booster, brake lines, wheel cylinders, calipers, discs, drums, and fittings. In addition, new springs and shock absorbers were fitted, the power steering was overhauled, and the engine received a new carburettor, an entire new exhaust system and a completely refurbished cooling/ heating system. A new wire loom was fitted, and all the dash gauges and switches were meticulously pulled apart and overhauled back to original condition.

The chassis was completely restored and painted in high gloss black, and the body received a full repaint
in a factory-formulated colour using all PPG two-pack products. The interior also got the same treatment, with new interior upholstery to factory spec and seat belts.

During reassembly, the FJ40 received a new set of rubber seals, new chrome work, glass, lights, badges, catches and latches, and a full set of Dunlop tyres. Finally, the finishing touch — a reconditioned factory winch assembly.

The only changes or improvements from the original vehicle were the design and installation of remote central locking, a GPS alarm, and a colour change to a factory option, Freeborn Red — with the help of Union Hardware and PPG, Mike had managed to track down the original factory formula.

A complete and comprehensive rust-proofing treatment was also carried out, something which the FJ40s never had from new — which is why they rusted so badly! — and, to top it all off, the finished painted surfaces were coated with a ceramic-paint protective coating, so, 20 years from now, it will still take pride of place in the Muir family garage,
as a fitting tribute to the several Land Cruisers that helped build the Muir family business.

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1968 Triumph Herald – Hark This Herald’s Angles Sing https://www.thesurgery.co.nz/services/restoration/1968-triumph-herald-hark-this-heralds-angles-sing/ https://www.thesurgery.co.nz/services/restoration/1968-triumph-herald-hark-this-heralds-angles-sing/#comments Thu, 15 Sep 2016 00:00:50 +0000 http://www.thesurgery.co.nz/?p=1843

When David Burke-Kennedy went to visit the owner of this beautifully restored Triumph Herald, he was surprised in more ways than one.

You can’t help smiling when you reach the end of the long driveway to Andrew Cowsill’s pristine 19th-century house. His shinier-than-new 1968 Triumph Herald sits beaming proudly in front of it — as if to upstage the beautifully restored and landscaped villa. If this was being written for a classic house, garden, and car magazine, you’d be hard-pressed to know which to focus on first — the romantic charm of the house, with its narrow staircases, low sloping ceilings, and walls and mantelpieces crammed with collectables from over several centuries; or the head-turning nostalgic linear Italian design of a car, which is almost a third its age? Given the title of this magazine, the Triumph Herald it is. And it is stunning, having been beautifully brought back to life by the talented team at e Surgery, after having had at least six previous owners.

It wasn’t what Andrew Cowsill was looking for. “I was looking for a first classic to work on, something like a Volkswagen Beetle or Karmann Ghia,” he admitted, “but the ones I looked at on Trade Me made me think, what a lot of work.”

“‘Other stuff you may like’ popped up on screen, and there was this Triumph Herald advertised for sale by The Surgery.

“I rang him and asked him to tell me everything that needed doing to the car.”

His reply was, “A few chips in the glass and some minor corrosion in the hubcaps.

“ That’s all. It’s not Concours condition, but you can drive it, enjoy it, and put it in a club show …”

“I began to bargain,” Andrew said, “but The Surgery informed me someone else was coming to buy it later that day. Well, he was asking less than what I’d budgeted to do up something else. So, I bought it there and then, unseen!” e little Triumph set him back around $13K, but it came complete with receipts for repairs and restoration over recent years of around $55K. Back in 1968, the car would have cost $2149 new — about $36K in today’s terms.

For Andrew, that day might have felt like all his birthdays had come at once — in fact, coincidentally, it actually was around his birthday. “And this was my present,” he said, laughing.

The Herald’s birthday was back in 1959 when the Standard-Triumph International company of Coventry launched it with a do-or-die fanfare of stunts and publicity that made the British motoring public sit upright. In late 1958, prototypes were driven from Cape Town to Tangiers — with every mile and stopover filmed for subsequent PR campaigning. Such was their performance, few changes were needed when the car went into production with its four-cylinder 948cc overhead-valve engine and manual four-speed gearbox.

The Herald was targeted at the emerging and increasingly affluent middle-class Briton — this was,
after all, the eve of the swinging ’60s, when people had more money, and London was about to be the capital of cool! e newly affluent wanted more than an everyday shopping basket of the type that was being churned out by some other carmakers for the ‘common’ people … And so, we saw the triumphant arrival of the Herald.

Commissioned to design the new model by the Standard-Triumph board, Giovanni Michelotti created an eye-catching two-door saloon with razor-edged style notable for its large glass area, which promised 93-percent visibility. Its engineering was also different from alternatives, with its body mounted on a separate chassis instead of being monocoque entire front hinged forward to provide engine access. Every panel, including the roof, could be unbolted — which made it easy to later create coupé, convertible, and estate-car styling, as well as the original two-door saloon.

It was no surprise that the Herald’s launch at London’s Royal Albert Hall on April 1959 was also an attention-grabbing stunt captured on lm. Four apprentices wheeled out the car in sections and bolted them together in three minutes. e end product was subsequently driven right across Europe, virtually as assembled.

The car was promoted and perceived as having a certain fashionable chic at a time when being fashionable counted — in music; lifestyle; and, of course, fashion itself.

While praised for its Italian-inspired looks, easy driving, visibility, easy access for repair, and a turning circle so tight that the car could almost be driven up its own exhaust pipe (it boasted the smallest turning circle of any production car at the time), the 25.7kW (34.5bhp) Herald was panned for its average performance, handling, and high price. It was initially a slow seller and quality was adversely affected as production was stepped up to meet demand.

At the beginning of the 1960s, the Standard Triumph Company was hitting the wall financially. Leyland Motors took over, injected much-needed cash, and redeveloped the Herald as 1200. Launched in 1961, it featured a more powerful 29kW (39bhp) 1147cc motor; better seating; better performance; minor embellishments, including
a simplified grille, rubber bumpers, and — what would later prove an attraction to Andrew Cowsill — a wooden laminate dashboard; as well as overall improved quality. Sales picked up at a time when
the likes of Ford and others were launching new small models such as the Mini.

Until 1971, when production ceased, almost 600,000 Heralds were produced and exported — many as complete knock down (CKD) units for local assembly in countries such as Australia, New Zealand, India, Ireland, Malta, South Africa and Peru.

“ They were probably the Suzuki Swift of their day,” said Andrew Cowsill. His previous ‘classics’ were nothing like this. His first car had been a ’55 Beetle, and this was followed by a MkI Ford Escort and an awesome Audi 100 Turbo, which exploded and died in grand fashion on the Auckland Harbour Bridge.

Back in the day, his father owned a Triumph 2000
and a string of MG T types — TC, TB, and a TD in Palmerston North. e car enthusiasm carried over to Andrew’s brother, who went the V8 route, and his sister has an MG.

“I wanted a car with a wooden dashboard and leather upholstery,” Andrew said, laughing, “probably influenced by working over varsity holidays as a car groomer at Archibald and Shorter.”

The Triumph doesn’t have the leather — genuine red vinyl instead — but it does have the wooden dashboard punctuated with a few knobs and buttons to operate single-speed wipers, choke, headlights, and heater — for the windscreen fan, not the passengers.

“I bought it for the condition and what I was getting for the money not because I wanted a Triumph, but I came to like it — in particular, the 1500 Dolomite motor and all-synchro gearbox instead of the 1200cc the standard Herald came with. It’s not fast by any means, but it keeps up well with traffic, and, because it has independent suspension, it’s entertaining on a twisty road — it gets along at a fair clip.”

“I drove it back from Wellington with Dad after I bought it, and he reminisced about old British cars and he gave me tips about looking after this one. Done a few long trips — boiled the brakes going from Auckland to Napier, so they’ve been converted from drums to disks.” He now carries enough spares and an original toolkit to virtually rebuild the car on site should he need to.

But how did he find a car in this condition?

A Hong Kong-based client had contacted The Surgery saying she’d bought a Triumph Herald online in New Zealand and that she wanted them to restore it “back to its former glory”. She told The Surgery that it would be only be used for future planned summer vacations in New Zealand with her partner. e time frame of the restoration was to be about three years.

The Herald was subsequently transported to Thee Surgery, where the team commenced the disassembly and assessment of the car. It turned out to be a nice original car from the start, but it was rather worn out and had a fair amount of rust in most areas.

After emailing numerous photos, options, estimates, and quotes to the owner, The Surgery received a reply saying, “Please go ahead, I want no stone to be left unturned, I want an as-new Herald,” so the project began.

The restoration work was carried out over the following three years. All work was completed in-house at e Surgery, with literally hundreds of progress photos emailed to the owner during the restoration, resulting in a very satisfied client at the end of the three years. Finally, the Herald was completed and ready for delivery.

Then, out of the blue, The received an email from the owner saying that their circumstances had changed and that they no longer had a use for the Herald. She then asked The Surgery if they could sell the car in New Zealand and wasn’t concerned about the price but wanted it to go to a good home, someone who would appreciate it.

Initially, The Surgery considered taking over the ownership, because the team loved the little car to bits, but logic stepped in and he decided that they already had too many cars, so it was listed for sale in New Zealand Classic Car magazine, and, within a couple of days, an appreciative new owner was found — Andrew Cowsill. Since purchasing it last year, Andrew’s modified and dressed it up for touring — fitting bigger 175x17x13 tyres with whitewalls on larger Triumph Vitesse rims. Other modifications included an alternator and halogen headlights, and he plans to install a Triumph Spitfire diff. On the motorway, it’s easy to see why the car has become Andrew’s weekend-driver ahead of his company seven-seater SUV with technology that blocks out all sound and feeling, as do so many of today’s executive vehicles.

The Herald is fun. The motor rasps noisily and determinedly like Barry White with bronchitis but without the coughing, and the ride is rm and nowhere as bouncy as you might expect from a light car of this era. Performance is also quite respectable — the car pulls and handles well when you need to accelerate from 80 to 100kph, and it certainly won’t have you holding up a line of traffic as you wind your way up the Rimutakas. Coming down the other side would also be quite entertaining, thanks to the car’s independent suspension demonstrated on early black-and-white TV commercials with a Herald bouncing down steps, its driver in pursuit of an attractive woman.

As a Triumph owner, Andrew soon discovered the immense support available from the Auckland Triumph Club. Apart from outings — many impromptu — support ranges from advice and resources available on anything from wheel alignment to general care and maintenance and parts sources. And he’s made many friends. Member Steve Douglas, a mechanic who works from home, has an encyclopaedic knowledge of Triumphs and a seemingly inexhaustible supply of parts, and he’s helpful to everyone. He is also an avid collector of the Triumph Vitesse, a sporty V6 derived from the Herald.

Andrew’s Herald quickly attracted attention when it arrived in Auckland and took out the club’s show ’n’ shine awards, trophies for which are proudly displayed in the old villa. “ those years of cleaning Jaguars over the holidays paid off,” he quipped.

If there’s a downside, it’s that the car is too approachable. “Whenever we park, someone approaches us with the news that somebody they know had one: there are traffic light conversations, hand waves … never had that before with any old cars.”

“If you’re in a hurry to get somewhere, don’t bet on doing it,” he says. “People approach you all the time in service stations. eir mother, sister, friend, the family had one back in the day, and so on. They wave at you in the traffic, almost run others o the road as they stare at the car — they want to chat when you’re stopped. I’ve been stopped by friendly cops when the speed’s been a little more than I realised. ey had aunties who owned one … and I got warnings.”

The odometer reads 45,672 miles (73,501km), though, on the original motor, it did a lot more according
to the papers. But it’s only needed three oil changes over the 5000 miles Andrew’s driven. Now he’s planning to ship the car overseas to take part in classic rallies.

The Surgery is restoring another for a club member, finishing it in the same Cactus Green colour. No doubt it’ll be another Triumph of restoration.

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1985 Rover 3500 Vanden Plas SD1 – Revolutionary Rover https://www.thesurgery.co.nz/services/restoration/1985-rover-3500-vanden-plas-sd1-revolutionary-rover/ https://www.thesurgery.co.nz/services/restoration/1985-rover-3500-vanden-plas-sd1-revolutionary-rover/#comments Mon, 23 May 2016 00:00:04 +0000 http://www.thesurgery.co.nz/?p=1831

This Rover SD1 has been part of Michael Ahie’s family since his grandfather drove it o the showroom floor over 30 years ago. He shares the story of returning the Rover to its former glory

The bright-metallic-green Rover SD1 looked like something from outer space — well, it did to me when I first saw it at the end of our driveway with my grandfather at the wheel.

Growing up in a small rural community in Taranaki in the 1970s, my grandfather’s new Rover SD1 caused quite a stir when it was rst sighted in Opunake. It was 1979, and I was 13 years old. In those days, my dad drove an HG Holden ute and my mum, a Vauxhall Chevette. A Rover SD1 was very exotic in small-town New Zealand back then.

My grandfather was known to everyone in town as ‘Jim’, and to all his whanau as ‘Pa’, and, when he pulled up at the end of our driveway in that space-age Rover SD1, I was hooked. He took me for a ride. I’ll never forget that first cruise down Tasman Street, with him at the wheel, and me looking at all the gauges and switches and listening to the purr of the engine. My love of cars was well on its way to full obsession. My grandfather owned an SD1! is meant immediate street cred to me, his grandson.

A few years later, Pa bought another Rover SD1, registration number MG261. is time, it was the top-of-the-range 3500 Vanden Plas, the Series II version lavished with everything 1980s technology could o er:
air conditioning, headlight washers, electric and heated mirrors, fog lights, power steering, central locking, electric windows, an electric sunroof, a leather steering wheel with tilt-and-reach adjustment, front and rear reading lamps, a burr-walnut fascia and door inserts, rear passenger heating, an Alpine radio/cassette with four speakers, tinted glass, a front spoiler, and — my favourite feature — a trip computer with a stopwatch and … a 240kph speedo. Wow.

By this time, I was at university and didn’t see my grandfather as much. It was the last Rover he owned, and, after his passing in 2002, it sat, a little forlornly, under a few blankets in a shed on our farm back home.

In 2007, I was standing around the car with my uncles, Terry and Joe, and I (quite innocently) asked, “What are we going to do with that?”

Uncle Joe replied, “You want to take it home with you?” I lived in Wellington. I said, “Really?”

“Really,” he replied, “and bring it back when you’ve had enough of it.” at was the start of an eight-year restoration project.

It was my grandmother who actually wrote out the cheque to buy MG261. My cousin Nicola found the original purchase receipt in some oodles. My grandmother’s name was Alice. She always had a blanket over the back seat to protect the velour, and would often sit in the back with an eye on the speedo; Jim got a short sharp order to slow down if the needle even approached 101kph.

In mid-2007, I went back up to the farm to trailer the car to Wellington. I found it to be in a sorry state. Eight years of sitting idle had not been kind. A family of mice, long deceased, had made a right mess of the interior. It stunk, and there were nests in the dash where the clock used to be. e registration sticker on the windscreen had an expiry date of February 1999. Anyway, after a jump start, it red into life remarkably easily, and I drove it onto the car trailer — after a quick squirt up Opua Road, just for old-time’s sake.

In late 2011, I rang my dad: “Dad, I’ve still got Pa’s Rover in the garage.”

“I know that, son.”

“I’ve done the sums, Dad. It will cost me heaps to x it properly, and it will be worth less than restoration cost, and I’m feeling guilty about it, and Janine’s car is outside and I haven’t got time, and …” On and on I went, with a long series of excuses.

“Well, sell it then,” he said. ere was a long pause.
“I can’t sell it, Dad! It’s the last car Pa ever owned!” Another pause. “Well, x it then,” he said.
And that was that. Decision made. The restoration was to commence immediately.

Disassembly started on Saturday, February 4, 2012. On the team, that day was my dad and my sons, Sam and Joe, who were 14 and 11 at the time.

Over the next six weeks, we worked every weekend and a couple of nights each week to fully strip the car. Tuesday night became the unofficial ‘Rover Night’, and mates and family members showed up to help out.

On Sunday, March 18, 2012, it was done, and we secured everything ready for the transporter to take the body shell to the team at The Surgery for the panel and paintwork. I had started a diary of all the work and recorded the hours done, and by who. e total disassembly time was 105 hours.

On Friday, November 23, 2012, the body shell came back from e Surgery. It looked amazing in its new coat (well, many coats) of Burgundy Mica Pearl. It was hard to believe it was the same car.

I had given The Surgery the challenge with the paint specification and the finish I wanted, plus every single panel had a war wound of some kind. The finished result is a tribute to the panel accomplishments of the team at The Surgery and their painting skill. The restoration team members were all very nervous about the rebuild — no one wanted to be the first to mark the perfect paint!

I needed an experienced mechanic to help out with some of the technical bits, and I was keen to have someone to mentor Sam, who wanted to rebuild the engine. I asked around, and Roy McGuinness put me onto a young chap named James Davison. Roy said he knew a thing or two about Jags and Rovers, and might just be prepared to join the Tuesday Rover Night crew. I met James, and things just went from there. He has been a major part of the build from day one.

He and Sam hit it o from the start, and their banter and general hilarity made the project a lot easier — those who have attempted a major restoration like this will know that motivation can wane at times; these two blokes kept me going, that’s for sure. e energy of this duo created one very exceptional Rover V8 engine.

The restoration carried on in earnest through the rest of 2012 and into 2013. In 2014, the SD1 took a back seat to another car project, then things got back underway in early 2015.

Dad and I decided we needed some more expertise to help us cross the finish line. I placed a ‘Help!’ call to Andrew Fox at Classic and Modern Motoring. He came over that afternoon.

Andrew has worked on our classic cars over the last 13 years. He became ‘Chief Drivetrain Finishing Officer’. With Andrew’s help, we sorted the last clutch, gearbox, and exhaust issues. We were ready for ignition.

The first engine start was on Thursday, August 6, 2015. It was a nerve-racking experience for me. Engine builders James and Sam didn’t seem too worried they had confidence in the build, obviously!

It all went well, other than the fuel pump failing after sitting around in the fuel tank for 16 years doing stuff -all — somehow, James procured a new genuine replacement one within two hours. We had fuel, spark, and plenty of oxygen-rich Wellington air. e fresh Rover V8 red up. It was a very special day for me.

The test drives around the block were event-free. James monitored engine functions. I couldn’t get the smile o my face. It ran perfectly. After 1700 labour hours, three-and-a-half years, some challenging days and nights, and a few laughs, too, it was done. Jim and Alice’s SD1 is back on the road, and she looks spectacular.

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1986 BMW M635 CSi – Majestic M-Sport https://www.thesurgery.co.nz/services/restoration/1986-bmw-m635-csi-majestic-m-sport/ https://www.thesurgery.co.nz/services/restoration/1986-bmw-m635-csi-majestic-m-sport/#comments Mon, 15 Jun 2015 00:00:44 +0000 http://www.thesurgery.co.nz/?p=1816

For many classic car enthusiasts, the catalyst for owning a car from a particular marque stems back to the first sighting of that model and the thought, ‘one day I’m going to own one of those’

Phil O’Reilly, the owner of this glorious BMW M635CSi, clearly remembers ogling a blue example at Team McMillan in Remuera Road, Auckland, back in the mid-’80s — a time when red braces and big hair were in, and the world was our oyster. A time when little old New Zealand was destined to be a global financial powerhouse of the world, yes, Phil remembers those days well, he was a bright-eyed university student looking at it all in awe and thinking he had missed the boat and wasn’t able to make his way as part of it.

Expensive luxury European cars were becoming commonplace on our roads during the ’80s, and one of the great status symbols then and now was a BMW. e E30 3 Series was current, and Phil remembers a mate who owned a red 325i coupé followed by a dark grey M325i. e design, the driving experience, the quality — but as far as Phil was concerned, the 6 Series stood at the pinnacle. He always stopped when he saw one (still does, as a matter of fact). e sleek lines, shark-like nose, cool boot spoiler and the drop-dead Hofmeister kink were all features that ticked the right boxes. Gentleman Jim Richards’ racing exploits in that stunning black JPS machine just added to the lustre of all things 6 Series.

You have to admire Phil for his dogged perseverance, as it was many years before he finally attained his dream car — and he’s reasonably con dent that he was the same one he saw at McMillan that day, as his Cirrus Blue M635CSi was sold new there. Phil doubts there are more than one or two NZ-new examples the same in the country, so that student dream may well have worked out more precisely than he could’ve imagined.

Chassis number 398 was one of the 20 or so M6s imported to New Zealand in the mid-to-late ’80s.
It completed assembly in Munich on December 29, 1986, and with typical German efficiency, was delivered to BMW NZ on February 5, 1987
Like all the other NZ-new examples, it was an earlier, chrome-bumper model, and as well as that Cirrus Blue paint scheme it boasted black buffalo-hide leather — a unique combination amongst the 524 RHD cars built. Back in 1987, the BMW came with a heavy price tag of $220,000. However, a quick sale was stymied by that year’s stock market crash, and the 635CSi didn’t and an owner until 1990.

Legend has it that the NZ M6s were actually destined for Australia, but were rejected due to Australian Design Rules. The cars were then redirected here at short notice, and distributed amongst BMW dealers for sale domestically. However, Phil reckons the Aussies have got their own back, as he knows of several NZ cars that are now in Australian hands.

When Phil first came into contact with chassis No. 398 some 15 years ago, he was actually going to do the same thing. He had a big corporate job in Sydney and thought ‘now’s the day’, and asked his brother to keep checking NZ Herald classifieds for an M635. Looking back, Phil concedes that it was a seriously stupid idea, even then, but he was a novice. Within a fortnight, Phil’s brother came back with not one, but two examples.

Phil had carried out some initial research on M6s and knew that the timing chain needed to be changed at around 160,000km. One of the examples had that work done after a complete engine rebuild when the old chain gave way, and the other had not had the work done yet, but had done 148,000km and was, therefore, was due for a replacement.

Phil wasted no time in flying back across the ditch to Auckland one long weekend to look at the latter car. It was best described as an honest example — not particularly clean or tidy, but with a full-service history, and it was totally original. It was also within his price range. Phil was immediately smitten, and as they say, love does strange things. He bought the car and left it at McMillan to have the chain replaced. Five figures and several weeks later it emerged t for another 100,000km.

According to Phil, there are a couple of lessons to be learned from all of this — “Don’t do what I did. It cost me!”

Luckily he had the wherewithal to restore the car properly after purchase but says it’s always best to do the right thing, join a local club and consult the experts. here are generally serious experts within classic car clubs who are only too willing to share their valuable knowledge, and if they don’t know the car you want to buy — walk away.

In this case, Phil shipped his dream car to Sydney and, as is the way with the truly naïve, thought it would be a simple task to make it perfect. In some senses it was. For example, most
of the M6s he’d seen needed serious detailing from top to toe for starters — not a problem for Phil, as he enjoyed spending literally hundreds of hours on the car restoring leather, cleaning and degreasing everything and polishing — all of which, he admits, made a real difference.

Phil’s not one to modify his cars, he certainly respects what the M engineers were trying to achieve, and wanted to recreate essentially the same car which came from the factory. He was helped by the fact that No. 398 was absolutely unmodified, just a bit tired, and set out with a vengeance to return it to factory fresh condition.
is is where he learned his second lesson — if you want to restore a classic performance Beemer (of any variety), get to know some fanatics at your local dealer parts department.

Phil found a friend at BMW in Sydney who was more fussy about locating the correct parts than Phil — he helped out by sourcing exactly the right windscreen-washer bottle (the 635CSi also has headlamp washers), and the correct oil cloth for the toolkit. Find one of those guys to help and, to a large extent, most of your problems will go away — just bring a very hefty chequebook.

Phil once heard a joke about BMW parts prices — if it’s a BMW part it’s expensive if it’s a 6 Series part double the price, and if it’s an M6 part double it again. He can attest to this and admits that some of the M6’s unique parts are eye-watering expensive.

This is where Phil learned lesson number three — don’t buy the best car you can afford, just buy the best car! If you can’t afford it, keep saving. You’ll save yourself a fortune in the long run. Phil modestly admits that his car is now one of the best in the country, maybe the world, but it cost him a lot of money along the way — if he’d bought better in firsts place that needn’t have been the case.

For example, some of the searches for parts became a real mission. e tyres are a famous example. e original M6s came with a 415mm rim. Remember, this was in the days when metric was going to take over the world, and Michelin was going to be at the forefront of it all. So, in what must have been a decision made over a couple of serious steins of ale, the Germans put metric tyres on the M6. Other well-known mainstream models that sported metric rubber include the largely unloved Ferrari Mondiale. To call these tyres rare would be something of an understatement, and most owners have since given up and gone to imperial wheels and rubber. But for Phil, originality rules, and he searched the world for 415mm Michelin TRX GT tyres. He finally found them on sale for a bank-busting price in the USA, bit the bullet and bought eight of them, just in case Michelin ever stopped making them.

One of Phil’s favourite searches, however, involved a stereo- cassette head unit. e unit in the car was cheap and nasty rubbish and, initially, Phil resigned himself to the fact that it would be di cult, if not impossible, to nd a genuine replacement. For once, BMW was unable to help, so he spent two years searching eBay Germany for the right unit — and it now sits in his car. Another fun search was for the original, and now exceedingly rare, red-handled (not left-handed) screwdrivers for the toolkit in the boot. Phil found them in the USA after years of searching and no, you certainly don’t want to know the price. Even Phil’s car-fanatic brother rolled his eyes at that one.

And yet another lesson Phil feels he should pass on — and a mechanic who loves your car as much as you do, and let them get on with it.

Phil relocated to Wellington in 2005, and despite completing a great deal of work on the car over the years, he decided it wasn’t enough. He wanted only the very best for his BMW, and says you can only go so far with this type of vehicle if you’re just handling ongoing minor work. At the end of the day, if you want a world-class example, a full restoration is called for. it happened over nine months or so during 2014, under the expert guidance of e Surgery in Tawa, Wellington.

Phil says he had confidence in going ahead with it because he found great partners with the team at The Surgery, who coordinated the restoration effort, Vijay and the team at Page European, who lovingly maintained the car while it lived in Wellington, and the Je Grey BMW team — also in Wellington, and absolutely committed to sourcing the right OEM parts to complement the restoration e ort, no small task given the age and rarity of these cars. Phil’s wife provided much- needed support too — a vital aspect, of course!

The full restoration started with the removal of the engine and transmission before the car was completely disassembled to a bare shell. e underside was stripped back and resealed with factory-correct textured stone-guard lm, whilst the front and rear suspension components were totally refurbished and repainted in the correct, factory satin black. e fuel lines and brake lines were replaced along with shock absorbers and brake rotors, and the brake callipers were reconditioned.

A new cross member was fitted, as poor jacking techniques over the years had caused a few unsightly dents. e body, including the engine bay, was treated to a fresh coat of Cirrus

Blue paint and the engine also received a thorough clean and repaint. Engine work was carried out by Page European in Wellington. e vital timing chain and top-end overhaul were done some time ago and no internal refurbishment was required, although all valves, hoses and peripherals were replaced if parts were available. Page European reinstalled the engine and transmission.

The original wiring loom was still in good shape and just required re-taping, with the factory original tape, of course. The perfectly original interior was left relatively untouched. e headlining was replaced, and a general tidy-up including cleaning and re-moisturizing the leather and dry cleaning the original carpets brought the interior back to its former glory.

Essentially, if Phil could replace any part with a new OEM part, then that’s what happened. is meant new trim, headlights, screens, bumpers, mufflers, shocks, brakes, and underside plumbing, just to name a few items. What wasn’t replaced was completely refurbished, cleaned and painted.

The restoration team was key, according to Phil. The Surgery continually challenged him to do the right thing by the car. They talked together often to discuss the best way forward, including jointly researching detail issues from all around the world. at led to a restoration which was completed to a very high standard, and at a reasonable cost. Everyone Phil dealt with was really proud to be part of the project, really enjoying the little moments of the journey together — finding a rare part, searching web forums for insights, talking to overseas experts, and researching why different things had been done to the car when it was at the factory.

The team effort was marked by an official ‘launch function’ at Je Grey BMW in Wellington late in 2014 with 70 friends attending, including (in typical Kiwi style) everyone from the mechanics and technicians who had worked on the car, to the German Ambassador. All three generations of the M6 were on display.

So, after having spent many years getting the car to Concours condition, would he do it again? “Absolutely!” says Phil, who reckons the project was one of the most fun things he’s ever done.

His wife says that he sometimes goes to where the BMW is parked just to look at it — but it’s as much about feeling good about what’s been achieved as it is about drinking in the M6’s well-balanced lines, not to mention recalling many spirited drives on the open road. Phil reckons the sound of that glorious Roche- designed six cylinders is still spine-tingling — and he enjoys it all the better for knowing all the hard slog he and his friends went through to get the car to where it is today.

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1967 Mercedes-Benz 250SE Cabriolet – Classic Cabrio https://www.thesurgery.co.nz/services/restoration/1967-mercedes-benz-250se-cabriolet-classic-cabrio/ https://www.thesurgery.co.nz/services/restoration/1967-mercedes-benz-250se-cabriolet-classic-cabrio/#respond Tue, 15 May 2012 00:00:18 +0000 https://www.thesurgery.co.nz/?p=2452

It’s probably fair to assume that the city of Auckland has more classic cars tucked away than any other in the country. Having said that, I reckon on a per-head

of population basis many other regions would win the
count hands down. Take the South Island as an example, I know it’s made up of several regions, but my guess is there are more classic cars squirreled away in barns, sheds and garages per head of population than just about anywhere else on the planet. I mention this because at NZCC HQ we’re continually sent a huge amount of emails and letters from enthusiasts all over the country with pictures of their wonderful classic cars, or their project cars in various stages of restoration. It’s fantastic to see. We appreciate everyone’s efforts in keeping us informed and look forward to featuring many of these cars amongst our pages in future.

That preamble brings us to Wellington and this beautifully restored 1967 Mercedes-Benz 250SE cabriolet owned by Mark Ford. Mark purchased our featured Mercedes-Benz via eBay from Louisiana, USA. From all accounts the car appeared to be in average to scruffy condition and was originally painted white with black interior. Further investigation revealed that Dr Carl Rice of Minneapolis, Minnesota, had originally ordered the car for tourist delivery, collecting it from the factory

on December 28, 1966 as a 1967 model year car. Dr Rice had specified it in off-white with an anthracite grey leather interior and manual transmission. A Becker TR Europa AM/ FM radio was added by a dealer in Germany while the Rices toured Europe in their new car.  Although a fairly basic specification, the car’s delivery price was US$10,000 (an auto transmission would have added US$339 to the purchase price) at a time when an E-Type Jaguar sold for US$5870!

Receipts obtained with the car show it stayed in the Rice family for some time before spending a few years in California during the 1980s. Eventually it found its way to Baton Rouge, Louisiana in the late 1990s — and it was from there Mark bought the car in 2007 with a view to restoration.

Once the Mercedes was in New Zealand, Mark carried out some initial disassembly at his home — removing the engine, transmission and some of the interior trim — which revealed the true extent of what would be required to bring the Mercedes back to life again. Like most older convertibles and cabriolets once they’ve reached that point in their lives that they have become unloved and neglected, water seeping in over time had led to rust slowly eating away at anything made of steel.

As with any old car, this Mercedes held a few surprises — both pleasant and unpleasant. It was built at a time when
the steel was good but galvanizing and rust protection were largely unknown concepts, and a life spent largely in the north-east of the US had taken its toll, with rot in the chassis and body. On the plus side, at some stage a number of exterior panels had been replaced, so they were largely clean with just a few scrapes and dents. The underside — with Benz’s notorious double skin construction — was another story. The initial assessment was that a baby’s head could be passed through some of the holes in the footwells and in other areas of the floor pan. With the assessment complete, the next step was to hand the Mercedes over to the talented team at The Surgery for a complete restoration. Their brief was to make this car ‘drivable first and watchable second’, and they delivered. Believe me, this car is stunning.

Once in The Surgery’s workshop, the car was completely disassembled until it was nothing more than a bare shell. This included the removal of many panels — including doors, bonnet, front guards and boot-lid — whilst the remaining bodywork was hand stripped back to bare steel. Unfortunately, this process exposed some fairly major rust in many areas, all of which needed to be permanently repaired or replaced to comply with VINZ certification requirements and, more importantly, to meet Mark’s high-quality standards. Some of the subsequent new panels and parts were manufactured in-house at The Surgery, and the remainder were sourced from around the world. Thankfully, almost all these chassis and panel parts are available either NOS or as pattern pieces as a result of a very active worldwide Mercedes- Benz restoration market. This also proved to be the case with everything from interior trim to mechanical parts.

The power of the internet brought everything together very nicely for Mark, who simply discussed his needs the team at the Surgery and then trawled the web, searching for the best options and pricing (and significantly improving his grasp of the German language along the way). The local Courier Post delivery guy became such a familiar visitor to Mark’s home that parts handovers were often accompanied by questions as to how the project was progressing.

And progress was being made, with the now bare shell mounted onto a special jig to support the body and chassis while the rusted floors, sills, rear quarter panels, rear inner guards, boot floor, engine bay panels and inner front guards — to name but a few — were cut out in preparation for new panel work.

The Surgery spent many hours welding and checking panel alignment, followed by the full replacement of floor panels (inner and outer), sill panels (inner, outer and jacking points), complete rear-quarter panels, complete rear inner guards, the
front engine bay sub-frame, rear boot floor area and spare wheel well. Serious test fitting and checking of alignment resulted in perfect door shut lines and panel gaps as per factory specifications. All work was closely inspected and certified to complete the VIN process.

The straightening, panel beating and finishing of all the bare steel bodywork to remove years of minor (and some major) panel damage was meticulously carried out. Special attention was put into getting the factory body swage lines just right. Once the body shell was complete then it was time to apply the PPG two-pack epoxy etch primers, high build undercoats, and two-pack clear-coat over base-coat to provide a show car finish not only to the exterior of the body, but also under all the wheel arches.

As the car had arrived on our shores in quite a rough state and with a number of non-original features, the owner
was relaxed about making it as he wanted, rather than sticking to strict factory originality. The ‘as delivered’ colour combination did nothing for him, so he was more than happy to recycle the car with the classic silver and black over red combination. Interestingly, this replicates a 1969 280SL he once owned and, although the silver is classic colour choice for a Mercedes-Benz — á la Silver Arrows — the shade chosen by Mark is actually a 1966–’73 Porsche blend, the same colour used on a 1973 911 he also owned.

Lastly, but definitely not least, full cavity wax rust-proofing of the upper body was applied using eight litres of product. New factory rubber seals and door rubbers were also fitted.

Repairs and metal finishing of bumpers, hubcaps and mouldings were then carried out and the wonderful chrome plating work was completed by Wanganui Electroplaters.

The next stage was to tackle the interior of the car, which included just about everything from new carpets, leather seats and door panels plus trim panels to the soft top identical to the factory original and completed in house at The Surgery.

The interior woodwork is a special feature of these hand- built Benzes and restoration of the veneer is not a task for the faint-hearted, as much of the interior wood sections are only 0.39mm thick and look to be a never-ending combination of compound curves. Many restored examples have the veneer over the instrument binnacle replaced with a vinyl or leather cover as seen on the contemporary sedans, as auto-trimmers throw up their hands at the thought of correct wood restoration or admit defeat after touching the finish with even 800 grit abrasive paper.

Thankfully for this example, Mark was not prepared to settle for second best and after some quick research through the internet unearthed Drew Tibcken, of Heritage Woodworks in Andrews, North Carolina, as the best in the business for these early Benzes. The finished handiwork on this dash testifies as to how well-deserved his reputation is.

The electrical system was next on the agenda, with at least 40 percent requiring a rewire to repair and restore the wire loom to as-new condition, including new and restored light fittings. The icing on the cake — a brand new, period-correct factory Becker radio.

Finally, in order to get everything back into roadworthy condition, the Mercedes’ suspension was completely stripped, sandblasted, repainted in two-pack gloss black and fitted with new bushes throughout. New shock absorbers and brakes were also fitted. And, of course, the car’s 2.5-litre straight six was treated to a full overhaul, as was the car’s four-speed gearbox. The engine and engine bay were totally detailed with fresh paint, plating where appropriate and
received lots of polishing — all of which means this 250SE’s under-bonnet now looks to be way beyond usual factory standards.

Once completion and assembly (including refitting the engine and running gear) was complete Mark reckoned the best part was the test drive, and he was delighted when he found that the freshly restored Mercedes drove just as well as it looked. The final step was to take the car through the VIN process — the Mercedes passed without a hitch first time.

According to Mark, his new ride is solid and usable on a daily basis without the need to make the usual concessions for the car being a convertible and over 40 years old. Having built it to be used, much of The Surgery’s best work on this Mercedes is not visible — and that includes the aircraft-quality space-frame, two-part primer, the waxed cavities and hand fabricated repair panels.

On completion, the official handover and unveiling of the fully restored Mercedes was held at the Museum Hotel, complete with cake-cutting, champagne and press photographers — all rather fitting for such an aristocratic cabriolet.

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VW Beetle – The Museum Art Hotel Wellington https://www.thesurgery.co.nz/working-classics/vw-beetle-the-museum-art-hotel-wellington/ https://www.thesurgery.co.nz/working-classics/vw-beetle-the-museum-art-hotel-wellington/#respond Sun, 15 Apr 2012 00:00:13 +0000 https://www.thesurgery.co.nz/?p=2446 For every person we meet and every car we feature in NZCC there is a special story – whether linked to the owner’s past or simply the tale of a burning passion to own a particular classic car. However, this story
is particularly interesting because not only does the owner of this fairly radical VW Beetle, Chris Parkin, have a keen interest in classic cars and motorcycles, he is also passionate about art and the Museum Art Hotel which he owns. Late last year we were invited to stay at the Museum Art Hotel in Wellington and spent some time talking to Chris, the man behind this unique establishment.

Chris was born in the UK and immigrated to New Zealand when he was four years old. He grew up in the small rural town of Otaki where he attended the local school, and went on to study at Victoria University in Wellington, graduating with both MSc (Hons) and BCA degrees.

Chris spent the early part of his working career in the banking industry before he started operating the Museum Hotel (formerly the Michael Fowler Hotel) as a result of a bet with the Secretary of the Internal Affairs Department. He was also the driving force behind an extraordinary engineering feat – this involved saving the hotel from de- molition to make way for Te Papa in 1993 by, quite literally, moving the entire hotel across the road on railway tracks; it is the largest building in New Zealand to be relocated. This rescue mission led to Chris being named Wellingtonian of the Year in 1993 and, in 2006, he completed a $29 million nine-storey expansion of the hotel to a mix of hotel rooms and apartments.

It is located in the heart of Wellington – New Zealand’s arts and culture capital – and Chris Parkin’s creative influence is felt throughout the luxurious Museum Art Hotel. The hotel houses an extensive, private collection of contemporary New Zealand art – over 80 pieces – collected by Chris over the past 17 years.

Chris commissioned New Zealand artist, Lynne Sandri, to create a Museum Hotel Art Guide cataloguing the art. Guests may use the guide and take their own leisurely tour of the diverse art works on display throughout the hotel.

In February 2010 Prime Minister John Key launched The Long Gallery – an external gallery display area exhibiting changing contemporary New Zealand art work.

The hotel also offers a highly personalised service that includes beautifully furnished suites featuring sumptuous, yet modern décor, characterised by attention to detail and an intimate feel.
For those wanting to indulge in the very best fine-dining experience in Wellington, Hippopotamus – the hotel’s award-winning in-house restaurant – features authentic French-style cuisine by Laurent Loudeac. Chris established the French-themed and Versace-inspired Hippopotamus Restaurant in 2007, and it has since grown to be the most successful hotel restaurant in New Zealand, with the major- ity of its business coming from outside the hotel.

The hotel is on Yahoo’s list of the world’s top 10 hotels.

When Chris is not busy running the hotel, or travelling far off the beaten track (usually on a motorbike – a recent trip saw him heading out in the northwest frontier provinces
of Pakistan, in Taleban territory, on his way through the Karakorum mountain range to China and eventually Tibet; a journey of 6000km), he is consistently serving the arts community through sponsorship assistance to many organ- isations, including a $100,000 donation to the Wellington Sculpture Trust, and for the past 11 years he has been sponsoring the top student at Toi Whakaari/New Zealand Drama School.

A Wellington City Councillor for nine years before retir- ing in 2004, Chris has also been involved in Wellington’s art and cultural scene for many years, and the Museum Art Hotel is a significant sponsor of visual arts, film making, theatre, music and dance, as well as having sponsored a number of motorcycle racers over the years. Currently he is chairman of the New Zealand Affordable Arts Trust (which runs the New Zealand Art Show for emerging artists each year), chairman of Wellington Venues Ltd (which operates all the large Council venues, including TSB Arena), chair- man of Te Whaia Services (which operates the schools of dance and drama) and is a director of Te Papa and trustee of the Hannah Playhouse (Downstage). Chris is also a lead- ing proponent of a new convention centre for Wellington, as well as a national art gallery, both of which would add significantly to Wellington’s growth prospects, and was recently awarded a Companion of the New Zealand Order of Merit in the 2011 Queen’s Birthday honours list.

You’re probably wondering by now how on earth Chris has time to enjoy his classic cars and motorcycles. To be honest, even Chris admits he doesn’t get to spend nearly as much time as he’d like behind the wheel of his Aston Martin DB7, BMW 535M (as featured elsewhere in this issue) or this stunning VW Beetle, which is used primarily as a promotional vehicle for the hotel.

The VW Beetle wasn’t actually planned as such, the idea only materializing when Chris decided to employ a sales and marketing person. After offering the position to the successful candidate, the subject of a company car came
up. Although a company vehicle wasn’t initially being offered with the position, not wanting to start a new working relationship on a bad note, Chris suggested that he’d sort something out, but made it quite clear that the car had to be something distinctive and representative of the hotel. After consulting a friend, the idea of a beautifully restored VW Beetle was considered. It all sounded too easy, they reckoned it would take about three months to complete and wouldn’t cost more than $20,000 – less than a good used car.

Unfortunately, the person contracted to build the Beetle turned out to be not as competent as they’d hoped, and Chris was forced to retrieve the basic car and all the bits and pieces which went with it – everything was loaded onto a trailer and taken to the team at The Surgery.

With a design brief to rebuild the Beetle as a combination of custom and retro styling with an artistic edge, The Surgery began work on the worn-out 1972 1302 Super Beetle, quite a rare semi-automatic model. The initial idea was that another company in Wellington would project manage the work while The Surgery was contracted to carry out bodywork and painting. However, as things turned out, The Surgery ended up completing all the work, including the project management.

The first task was to completely disassemble the Beetle, starting with the interior, dash, engine, transmission, glass, and chrome until it was just an empty shell. The bare shell was then acid dipped and sand-blasted back to bare steel.

Old battle scars and rust meant cutting out damaged sections from all four guards, floor pan, heater ducts, doors and quarter panels, these being replaced with fresh panels. To give a lowered appearance without turning the Beetle

into a hot rod was a difficult ask for The Surgery’s skilled team. They eventually opted for a retro look by cutting the complete roof off from the bottom of the screen pillars and waistline of the doors. Fifty millimetres was then removed from the pillars to lower the roof-line and a complete roof from a 1960 Beetle was then fitted. This model of Beetle was chosen because of the higher ‘crown’ in the roof panel and lower roof gutter line, thus enabling The Surgery to give the VW a ‘chopped’ roof look without sacrificing interior head-room. The Beetle’s glass was then either remade or cut down to suit the new opening sizes and shapes.

The end result makes you give the Beetle a double take – is it modified or not? It certainly looks different.

With all the panel work prepared and ready for paint – and with handmade period-style bumpers fabricated and installed – the next thing to consider was paint colour. The Museum Art Hotel’s official colours are black and gold,
so PPG two-pack high gloss/high solid jet black paint
was chosen. A retro-twist was added with the addition of hand-painted gold lace-work inserts on the car’s flanks, while specially-designed gold wheels completed the overall theme.

Mechanically, the Beetle wasn’t in the best shape so the engine was fully reconditioned with a few performance enhancements, including an electronic ignition system. Final detailing of the engine bay included gold-plating some items, whilst all the exhaust components were replaced with new parts, all of which were HPC ceramic coated.

The ‘bling’ needed to stop, so the Beetle’s brakes were upgraded to four-wheel discs and a completely new suspension set-up was installed and lowered using factory conversion kits.

The next item on the agenda was the electrical system – including the fitting of a new wiring loom with additional extra features including remote central locking, up-rated performance headlamps, interior LED lighting, remote interior UV lighting (for use at night when parked) and engine bay LED lighting.

The final task was to contrast the interior with the rest of the car, so it was treated to a complete re-trim in white leather with gold trim (set off by ultraviolet lighting at night), gold embroidery on the interior panels with the Museum Art Hotel logo, black carpets with gold edging, gold plated interior fittings, a gold chain link steering wheel and a custom sound system to complete the picture.

Two days before Christmas, three years ago, the car was delivered to the Museum Art Hotel unbeknownst to Chris. It was the night of the annual Museum Art Hotel Christ- mas party, and when Chris entered the hotel, there was
the Beetle in all its glory. Today, his only regret is that the Beetle should get out and about much more than it does – and, of course, he’d like to be driving it himself.

Nevertheless, the end result is a vehicle that attracts attention wherever it goes – it’s a genuine ‘one of a kind’, much like the Museum Art Hotel.

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1955 FJ Holden Ute – Bangers From A Banger https://www.thesurgery.co.nz/working-classics/1955-fj-holden-ute-bangers-from-a-banger/ https://www.thesurgery.co.nz/working-classics/1955-fj-holden-ute-bangers-from-a-banger/#respond Wed, 14 Mar 2012 23:00:30 +0000 http://www.thesurgery.co.nz/?p=1858

At NZ Classic Car, we’re always enthused and fascinated by the incredible variety of classic cars that exist in this great country of ours. They range from Austins to Zodiacs, Lamborghinis and Ferraris to Morris Minors and Javelins – and all

of them come with their own unique stories and with owners who are equally enthusiastic and passionate about what their favourite marque means to them.

Every once in a while a vehicle comes along that we’d consider unusual or unique for whatever reason, such as our recently featured aero-engined Riley or perhaps the cute, lime-green Eastern European Trabant that
we featured earlier in the year. And that brings us to this stunning

FJ Holden ute. As you read this story it’ll become rather obvious what makes it so unique, and a stand-out from the crowd.

It all started when Export Meat Warehouse, a national chain of 23 franchised and independently owned butcher shops, decided to create a totally unique mobile BBQ.

The idea for this BBQ was sparked by the story of an adventurous fellow from Australia called Tom O’Toole, a baker from Beechworth in Victoria. O’Toole travelled all around Australia in an old Model T van, even going to
the very northernmost tip of Australia where people said it couldn’t go. Hamish Preston, managing director of Export Meat Warehouse, was so inspired by Tom’s story that he decided to create something similar in New Zealand.

The Export Meat Warehouse head office team scoured the country for a suitable vehicle, and in addition Hamish Preston also approached well-known vehicle restoration team at The Surgery, to discuss ideas on a promotional vehicle based on a 1930s-1940s pick-up truck capable of carrying a portable BBQ in the back that could be taken out and set up at shows and special events.

Both Hamish and the team at The Surgery kept an eye out on local auction websites and in the Cars for Sale section in NZ Classic Car, looking for the right vehicle to use. After some intense searching finally, an FJ Holden ute came up for sale on the internet and both Hamish and The Surgery decided to go to Nelson, where the ute was located, to take a further look.

The old FJ was the perfect solution for what Hamish wanted to achieve and, after a bit of haggling with the owner, a deal was struck and the project began.

The vehicle the pair had finally settled on was a 1955 FJ Holden ute, a classic vehicle in every sense of the word.

The FJ has indeed become a celebrated Australian icon and, in fact, the trusty FJ undoubtedly played its part in cementing Holden’s place as building Australia’s most popular car. Today, Holden lovers, restorers and those wish- ing to modify this iconic classic recognise that unmistakable, era-de ning chrome grille and stylish monogrammed hubcaps. Indeed, that distinctive front grille assembly has since made the FJ one of Australia’s most familiar faces.

Once the FJ ute was in the hands of The Surgery, work began on turning this old banger into a mobile BBQ, a restoration project that would last seven months.

The task in hand was to create a vehicle which a wide sector of the New Zealand population could relate to, plus it needed to have the feel of those old-time Kiwi golden summers – and so the task was to transform an old, retired icon into a genuine working classic.

Hamish’s requirements for the vehicle were quite specific and included such things as upgraded brakes, suspension, engine and gearbox, but the vehicle still had to retain its classic personality.

The FJ ute also needed to be user-friendly and reliable, as it was to be driven by a wide range of people and be capable of carrying heavy loads at times.

Another requirement was that the old FJ had to have a few creature comforts on board (for those long trips up country) and be capable of keeping up with the general traffic on the roads.

Last but by no means least, it needed to be self-contained with a complete BBQ that could be easily and quickly
set up and put away and, just as importantly, the ute still needed to look original to the untrained eye.

The first job on the agenda for e Surgery was to develop a suitable design that was not only practical, but that would also comply with the requirements set down by Hamish and his team at the Export Meat Warehouse. The Surgery produced dozens of sketches, working drawings and innovative ideas which ultimately came together to produce an end result which has since become a highly sought after (and very cool) marketing tool for Hamish. Basically, the result of The Surgery’s work ended up being a cross between a camper van, food catering vehicle, mobile marketing machine and classic car all rolled into one – complete with a bright red paint job and whitewall tyres.

In actual fact, the FJ Holden was in fairly tidy original condition, albeit a little worn, providing The Surgery’s team with a good base to work from. The first step was to completely strip all the mechanicals, interior, engine, gearbox, suspension and electrics out of the ute so that design work, mechanicamodificationsns engineering, upgrades and over- hauls could be carried out.

The next step was to test t the entire new drivetrain that included a fully reconditioned 3.3-litre (202ci) Holden engine with a modified sump and oil pick-up. e new engine also featured new standard 202 engine mounts, new heavy-duty 120-amp alternator and a Holden VK Commodore electronic pointless ignition distributor. A heavy-duty radiator with a thermostatic controlled electric fan was installed to take care of the cooling department.

e engine was then mated to a Holden Commodore ve-speed gearbox, and a heavy-duty clutch was added to take care of any extra weight. e next step was to install the ball-jointed (from original king pin) front suspension, but not before the front cross member was upgraded to

a Holden HR unit. New gas shocks and front sway bar
were also fitted, while the rear suspension received a set of adjustable heavy-duty gas shocks. e front brakes received a disc brake conversion complete with new callipers, brake booster, master cylinder and overhauled pedal box assembly, all courtesy of Holden VK Commodore.

Once the drivetrain was completely installed and fully

checked to ensure everything worked and operated as it should, the vehicle was completely disassembled again so the panel work and straightening could commence.

e bodywork on the FJ was fairly sound to start with for its age, considering that The Surgery and Hamish had spent some time looking for a good example. e Surgery discovered that the FJ ute was previously painted white, and there were visible areas of surface rust once the shell was stripped back to bare steel which required a small amount of cutting and welding operations before it was repaired and straightened.

When the body was perfectly straight and prepared for painting it was then fully sprayed in Export Meat Ware- house colours using PPG two-pack products, and the company graphics and sponsor logos were applied. e body was also fully rust-proofed and under sealed at this time.

Now the body was painted it was time for the reassembly of all the new and revised mechanical and suspension components, as well as a 12V electric heater/demister, remote electric central locking system, up-rated headlamps, 12V system and heavy-duty 12V starting battery. Originally the FJ didn’t have indicators, so an indicator switch was designed and fitted to the steering column and the indicators placed inside the front side lamps and tail lamps. e windscreen wipers were converted from vacuum to dual speed electric wipers and inertia seat belts and centre lap belts were fitted. To add the finishing touches to the ute’s interior, a CD player with iPod plug and two four-inch speakers were installed in the doors.

Once the FJ Holden Ute was fully restored and looking a mil- lion dollars, the hardest and most challenging component of this entire project had to be tackled – installing the BBQ.

After much research and countless design concepts, The Surgery created the overall effect for the canopy. e look was one of a stylised wooden ‘crate’ as seen back in the 1950s, complete with black boards on the sides for those special sale items. e canopy has exterior low watt- age lighting that lights up the black boards at night, plus red strip lighting around the underbody to highlight the flames which can be left on at night when the FJ is parked up in high traffic areas for maximum exposure. ey can be turned on and o using the remote central locking control. e canopy doors open upwards and lock together to create large signage areas.

They also have exterior speakers concealed inside which are linked up to a second sound and PA system located inside the canopy.

In a matter of minutes, with one quick action the entire kitchen-catering contents of the canopy slide out on a deck that carries a self-contained stainless wash hand basin (with electric water tap), a water tank with hot and cold water, a full six-burner BBQ, cook/prep top/storage drawer and 12V fridge. All ready for use straight away.

is amazing creation also includes interior adjust-
able LED lighting, a built-in electronic Intellicharge self-charging system with two storage deep-cycle ‘house’ batteries that allow the complete system to run under its own power for up to nine hours. e batteries can recharge while driving or can be plugged into 240V mains. There is an on-board petrol generator t , if required. In addition, there are inbuilt safety features such as an electronic gas extractor, re extinguisher and the main power switch that can use the ‘house’ batteries to start the FJ if the starting battery runs at. Full test and certification of complete vehicle and modifications were completed.

Called the BBQ Ute (registration IBBQ4U), the BBQ Ute is totally self-contained with its own fridge, hot running water, gas BBQ, workbench and sound system, all the equipment needed to cook a superb banger.

Export Meat Warehouse has selected KidsCan charity as its primary charity of choice, which provides disadvantaged Kiwi children with shoes, raincoats, food, and school books – it’s also supported by the All Blacks. But there is also room for local charities to be supported.

e FJ Holden BBQ Ute will be used at charity events right around the country, as it travels to members’ stores, and to special events. Whenever it is out on the road, the ute attracts a huge amount of attention – it really needs to be seen to be believed, as it’s one of those interesting, very unique vehicles that we can all appreciate and admire.

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