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Previous Page 1960 Austin Healey Bugeye Sprite restoration Dec 2005-June 2007 Next Page
We are begining a "rotisserie" restoration on a 1959 Bugeye Sprite.
Rotisserie made from 2 engine stands and some backyard enginuity. Rear rotisserie mounting. Using the rear overrider mounts and then drilled two additional holes in the license plate area with a reinforcement inside the
front mounting directly to frame members. At the media blaster to remove all paint, bondo and surface rust. A nice, bare shell to begin a nut and bolt restoration. Only slightly more rust than what was expected.
Both floor will need to be replaced. Here we have drilled the countless spot welds on the drivers side floor and removed the bulk of it. Some minor trimming will follow, before we fit up the new floor.
Pre-fab door hinge patch in place, ready to weld. Taking a break from the nasty rust repair, we take on a pleasant task of re-finishing the dash. All unnecessary holes were welded shut, new vinyl covering was glued on. The signature on the left side is that of Donald M. Healey son, Brian All gauges have been rebuilt, switches tested and replaced where needed. The car will not be fitted with a heater, so we re-arranged some of the switches and knobs, namely the starter cable location.
All the seat frames and pans were sandblasted, and powdercoated gloss black. Here we have all the components for Motorcar Garage upholsterer extraordinaire, Ed Sweeney to work his magic and bring it all together. Luckily we were able to re-use the existing foams. New Moss Motors vinyl seat kit. You'll notice these are not true Bugeye MkI seats. They came from Mk II Sprite, the design of which I prefer over the Bugeye pattern. repairs to front inner sill and outer rocker.
A section of a new rocker was used for a patch. We will also need a small patch from that same new rocker for a small rear patch. Nice tight door gap achieved. Note the rear section of the outer rocker has been cut out. A small patch will be welded in place.
Completed door post/rocker panel repairs. Next we will move on to the lower rear fender sections, both in front of and behind the wheel opening. Cutting out rear dogleg area.
Rough cut complete. Final finshing needs to be comnpleted and several patches fabricated. Ready for a skim of body filler and we are all set. The final
It was necessary to cut out the inner fender lip and fabricate a new one. Inner fender lip welded in place along with the inner panel, which was available from Moss Motoros.
rear patch installed floor/chassis rail repair welded in place Finally new floor clamped in, ready for welding.
Rt side front rocker panel rust. This will be cut out and replaced with a section of new rocker panel. bottom of right quarter panel, and rear rocker section rusted, and will need to be cut out and replaced.
Finally at the body shop ready for paint. painted!
coming together
first time around the block Test run Interior completed except for door panels
99% finished The Frogeye lives!
The restoration was completed in time for the International Austin-Healey Conclave in Burlington, VT. We were very pleased to receive 1st Place in the Mk. 1 Sprite category.
 
Owned and Operated by: Peter Cosmides, Maple Shade, NJ
Phone: 856-667-6657 | Email: motorcargarage@verizon.net