Rover 416 GTI Auto - Restoring an old friend

Want to share photos and details of your projects? Then post them here.
Post Reply
User avatar
Plodder
Club Member
Posts: 508
Joined: Sat Nov 05, 2016 11:23 am
Location: South West

Rover 416 GTI Auto - Restoring an old friend

Post by Plodder »

Image

I've finally been able to workout how to download a photo of my Flame Red Rover 416 GTI Auto on to the forum so I've decided to come out of the woodwork and share my restoration project .
Some of the work shown here will be retrospective , with work carried out earlier this year, the rest will be the long list of jobs to bring the car back up to a good standard.
It was registered in 1991 and I brought the car in 1997.
It had 3 previous owners and it came with 33k miles on the clock and was in good condition although already some of the panels were already different shades.
By 2006 it become our 3rd car and went through a period of being stored in a variety of location . Unfortunately one of these included a car cover under an oak tree at the bottom of my parents garden. This caused significant damage to the bodywork and lead to a lot of time spent unseizing brake callipers.
By 2016 the car had done 140k and was looking a little worse for wear so I decided to move it in to a dry lock up garage and work on restoring it.
By this stage the list of tasks was quite long.
The sills had rusted through on previous occassions ,in the usual places , and a variety of different quality repairs had been undertaken over the years.
The paintwork on the roof and parts of the bonnet has been damaged by the movement of the car cover during storage and there are now a number of small "hailstone" dents on the roof and bonnet caused by acorns and twigs falling from the oak tree during it's storage.
During storage a squirrel decided to make it's home in the air box and use the insulation from the bonnet soundproofing to make it's nest , it however doesn't seem to have gnawed it's way through any of the cables or pipes.
The original wheels were also looking a bit worn with the paint peeling and corrosion setting in. A piecemeal approach to having them recoated wasn't really successful either.
So the car was a bit of a mess although the picture above, taken in 2017 , appears to show a car in reasonable condition.
Since the start of the year I have made some progress , although a recent discovery of a rust hole in the bottom of the A pillar caused by a rather large dollop of windscreen sealant collecting water has set the project back a bit.
Some people I guess would suggest scrapping it and going to look for a low mileage example that's been kept in a dry garage for years but somehow to me it wouldn't be the same and the number of examples of this model on the road is very small so the scrapyard is going to have to wait a bit longer for this one.
I've allocated myself some money for the project and hope it's enough to cover the bodywork repairs and hopefully a full respray (i'll leave these bits to the professionals) at the end.
Last edited by Plodder on Sun Jul 03, 2022 9:23 pm, edited 3 times in total.
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 :)
Cthomas
Forum User
Posts: 131
Joined: Sat Jul 25, 2020 6:21 pm
Location: Kent

Re: Rover 416 GTI Auto - Restoring an old friend

Post by Cthomas »

I had a 420 gsi in red and the same alloys which I miss
Rover 216 vdp 1990
Old ones
Rover 216 vdp 1986 my dads last car
Rover 420 gsi 1992 miss this one
Rover 214 sei 1995
Rover 820
Rover 3500 vp sdi
Rover 2600 sdi
Paul_1978_yorks
Club Member
Posts: 2921
Joined: Mon Jan 22, 2007 11:11 pm
Location: Wakefield, West Yorks
Contact:

Re: Rover 416 GTI Auto - Restoring an old friend

Post by Paul_1978_yorks »

Great post - looking forward to seeing progress.
Current:
2018 Volvo V40 Cross Country
Former:
214 SEi x4, 216 SLi, 216 Cabriolet, 416 GSi, 420 GSi Tourer, 25, 45, 75
User avatar
Plodder
Club Member
Posts: 508
Joined: Sat Nov 05, 2016 11:23 am
Location: South West

Re: Rover 416 GTI Auto - Restoring an old friend

Post by Plodder »

So I guess my restoration journey began 4 years ago with the  purchase of a couple of new brake callipers and an exhaust manifold cover (which was less than the price of a tin of paint using the Rimmers on-going "Mega Clearance sale" )
The calipers stopped the seized brakes / hot wheels episodes which had plauged the car since being stored outside.
During a visit to a local garage and with the car was up on the ramp the owner commented that the bottom of the radiator and the auto transmission oil pipes to the radiator were well corroded and should be looked at before too long. A quick rub  along the  bottom of radiator resulted in rather a large handful of rust and  a clean up of the transmission oil pipes revealed what looked very much like a pin hole and a dark area of leaking fluid.
Not wishing to damage either the engine or the transmission with a sudden loss of coolant or transmission oil the search for a new radiator and pipes was started.
In fact I had been looking for a radiator for some time but had stopped at spending £250 + on one from Rimmers. The problem  now was I couldn't  find one anywhere.
Auto transmission  radiators are rare beasts  indeed , although a later visit to a radiator repairer suggested it was possible to stitch the transmission oil cooler part of the radiator onto a new manual car radiator. This might be an interesting experiment with my old radiator when I get time.
Struggling to find a replacement radiator  I then started looking at places to refurbish my existing one , fortunately  for me a post on the forum resulted in me obtaining what was an almost brand new radiator including fan and oil transmission pipes.
Removing the radiator is very straightforward  and once removed it was clear the poor state of the radiator with perhaps 1/3 of the cooling fins corroded out.

Image


With the old fan transferred over  I gave the oil pipes a clean up and sprayed then with silver Optima high temperature paint from Euro Car Parts to keep them from further corrosion.  However this paint turned out to be less than useless and by the time I had put the radiator in and out a few times  I reckon  most of the paint had rubbed off. However since the car is now kept in drier conditions hopefully it will last more than 30 years.
The fan and pipes were fitted to the new  radiator easily and the whole assembly looked very smart.

Image


Reinstalling the radiator was straight forward although I realised I hadn't recorded which way round the oil transmission pipes were connected. It's possible it doesn't matter but it may also have affected the level of transmission oil cooling . A quick post on the forum resolved the problem with the o/s pipe going to the bottom radiator connector and the n/s pipe going to the upper connector

Image

 Running the car up to temperature I then noticed the expansion tank hose/bottom hose joint was weeping. I have struggled to find a replacement  bottom hose or  an aftermarket connector that had a similar configuration so I have made a temporary fix on the leak with some hose mending tape.

Image

 Subsequently I've found a corner section of hose from a T series 2 litre engine (another " Rimmer Mega clearance " sale bargain ) .
I just now need to get some standard aftermarket hose and connectors to make up a new bottom hose and I'll do this when I upgrade the coolant next year with possibly some non water coolant you can buy

The car now runs much cooler and the fan only kicks in when the car is taken for a run out.
Last edited by Plodder on Fri Jun 04, 2021 7:22 pm, edited 1 time in total.
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 :)
User avatar
Plodder
Club Member
Posts: 508
Joined: Sat Nov 05, 2016 11:23 am
Location: South West

Re: Rover 416 GTI Auto - Restoring an old friend

Post by Plodder »

Update on the dollop of windscreen sealant.
I cut away the excess sealant today to reveal the rust underneath.
Seems to be only on the off side and fairly localised but I have the feeling the screen will have to come out to allow a plate to be welded in place.
Back to the garage I think.
Watch this space!
Image
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 :)
User avatar
GTiJohn
Club Chairman
Posts: 7248
Joined: Mon Aug 16, 2010 7:01 pm
Location: Midlands

Re: Rover 416 GTI Auto - Restoring an old friend

Post by GTiJohn »

This looks like it'll be a fascinating series :D

You're right about the screen having to come out though... :sad
I like Twin Cams.... and Single Cams...and now Turbos
Mr Teddy Bear
Club Member
Posts: 2530
Joined: Sun Jun 10, 2012 3:01 pm
Location: Bristol

Re: Rover 416 GTI Auto - Restoring an old friend

Post by Mr Teddy Bear »

Don't use waterless coolant [ Evans springs to mind ] it's secret lies in it's poor heat transfer characteristics. The stuff leaves the heat in your block/cyclinder head instead of transferring it to the cooling system!
It's flammable and very slippery [like oil] banned by all forms of motor sport! :o
Teddy Bear

216 Sli SRS Charcoal Met 1996

214Si Silver? Tempest Grey 1993
User avatar
Plodder
Club Member
Posts: 508
Joined: Sat Nov 05, 2016 11:23 am
Location: South West

Re: Rover 416 GTI Auto - Restoring an old friend

Post by Plodder »

Thanks for the comment on non-water coolant .
I had seen various negative comments on its use.
I'll stick to a good quality coolant in future and change it regularly on its annual service.
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 :)
User avatar
Plodder
Club Member
Posts: 508
Joined: Sat Nov 05, 2016 11:23 am
Location: South West

Re: Rover 416 GTI Auto - Restoring an old friend

Post by Plodder »

Update on the rust hole caused by the windscreen sealant dollop.(see above photo)
Silsoe Classic & Modern who have done some excellent work on replacing some poor sill repairs (i will post some picture when I get to that stage of my restoration!)have come back to me.
So its wing off, bumper off, door off, windscreen out -to allow access during welding - interior pillar trim off and dashboard released but not out to allow them to get a blanket in to protect the dash during welding.
I’ll probably have the other wing off at the same time so they can repaint both sides at the same time, which they believe they can do within the current estimate .
This is definitely a case of the heart ruling the head when it comes to making a decision about going ahead with the repair🤣
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 :)
crepello
Club Member
Posts: 2042
Joined: Thu Feb 18, 2010 2:47 pm
Location: Mid-Herts

Re: Rover 416 GTI Auto - Restoring an old friend

Post by crepello »

Plodder wrote: Sun Oct 11, 2020 10:09 am This is definitely a case of the heart ruling the head when it comes to making a decision about going ahead with the repair🤣
I'm in that place with mine, moreso because they are lower-spec examples.
BTW, the doors will lift off the hinge pins once opened past a certain angle. Preserves alignment when they go back on.
Post Reply