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Project Kikker.

Part 1.

2004.

December. Bringing her home. The 1962 DAF Daffodil deLuxe (Type 303), as purchased in Ridgefield, Connecticut.

Kikker is ready to go inside.

It may not look it but this car already has all new patch panels installed, new tires and a complete new interior.

2005.

Starting the strip down process to do a proper restoration.

Kikker needs a good sanding...plus a whole lot more. The car is a mess.

Body all stripped out and sanded down to bare metal.

The 750cc motor pulled out.

Stripping the motor, not sure what I'll find inside because it sat so long.

Centrifical clutch looks OK but needs to be cleaned up and shoes will need to be re-lined.

Checked out the Variomatic and everything is loose and working good, just needs a good service.

The body getting stripped and gone over with a fine tooth comb.

The back end getting some detailed attention.

The hood is a little rough right now.

Some touch up is needed near the lower panels.

2006.

The passenger side panels getting smoother.

The rear section getting some more detailing.

Repairing some defects at the rear quarter panel.

Same damage on the other side being taken care of.

2007.

It sure is handy to have a lift now, and it can be moved anywhere, including outside. 3 Ton Capacity, 115 volt Hydraulic system.

Body work is shaping up nicely.

Nice coat of "Stone Guard" paint on the new floorboards.

Time to take a little break and go for a ride.

Kikker on display at the DCA MicroCar show in July.

Back in the garage again. The trunk lid is going to need some more work. I had it sandblasted inside and out.

The front bumper sanded down,it will need to be re-chromed later.

2008.

Cleaning up the inner wheel wells which will be painted to match the outside.

Lots of undercoating scrapped off. Everything is solid and clean.

Time do do some rear brake restoration on KIKKER. This is before; frozen cylinder and a lot of rusty parts.

Tear everything down to the bare shaft.

Everything newly painted, bearings repacked, seals replaced and new wheel cylinder installed.

A new brake system ready to stop on a dime. One down, three to go.

Completely restoring the parking brake system with new cables.
Since a lot of the parts are no longer available I have had to improvise on some clevis points.

Continuation of brake system. Next step is to replace all hoses and brake lines.
Since DAF used all British Girling parts for the cars it is easy to cross basic brake parts over to available UK pieces...
Rubber flex hose is from an Austin Healey Sprite and lines are 3/16" British standard available here (but not always in the correct length).

Due to the different lengths of brake line now available I had to fabricate an extension to the flex line holders.

Is this the Olive Green I want??? I don't think so....back to the mixing pot for this color.

The final color choice has been made. This is as close to "Oliva" green I have come and the match is really good.
I finished painting the engine compartment are so the motor can go back in when it is ready.

Kikker was taken outside for a little while...I needed daylight to mount the repaired headlight buckets.

Some of the key elements have been put back into the engine compartment.

Vacuum pot, battery tray, ground strap, heat intake, master brake cylinder, wire harness, hood release cable and heater cables.

After spending a week restoring an original Heat/Air exchange box I was able to install it back in the engine compartment.
The only thing left to hookup are the air hoses and it will be complete.

All the wires have been wrapped in plastic conduit, most of the brake lines have been installed and the new Heat/Air Duct tube is is place.
The engine compartment is now 100% ready for the motor.

Pretty rusty mess on the left front wheel and the Ball Joint boot is ripped...it's all coming apart!

Next project is the front Brake system which should be easy...but I also have to change out the Ball Joint which is going to be time consuming.

It did not take long to tear it all down for cleaning and painting...now comes the fun part! Surprisingly all the bolts & nuts came off easily.

Everything back together on the front brake and suspension. New Ball Joint, Flex line and brake lines.

The new wheel cylinder, springs and shoes in place. While the front drum is off I am also changing the wheel bearings.
These were easy to find here...luckily Daf used popular name brand bearings so they crossed over to new ones easily.

Front hub all complete including new wheel bolts and wheel bearings.

The "chassis" (Belly Pan) is also getting some needed attention. A layer of filling is being applied to hide edges of new floorboard panels.
The underside will look just as nice as the outside.

Belly pan is now complete and repainted. On to the next project.

Restored Daffodil Flywheel Housing with New Bearing and retainer clip. Bearing is an SKF (double sealed) # 6204-2RSJ, in case you are wondering.

Daffodil Clutch Housing polished and painted. If you attempt this, be sure to polish the inner surface where the shoes make contact.

Clutch Housing and Shaft bolted back together.

Outer Flywheel and Clutch Housing all complete and ready go back on the motor.

An inside view of the restored Clutch housing. I could not beleive how many small pieces were involved in this one part.
Total restoration time was about 8 hours.

Back of 750cc motor block. Rear crankshaft seal is going to be replaced, while it's all open, and everything has been painted up.
The new seal is SKF # 21627 in case anyone needs to change theirs.
Make sure the felt washer is also cleaned and re-oiled before putting the flywheel back on.

Flywheel finished and installed with new bolts. Next step is to have the clutch shoes re-lined.

The eight (8) Clutch Shoes have been cleaned up and are ready to be re-lined locally.
They are not that badly worn but some are dried out and cracked.

I just got my shoes back from the re-liner. They did an awesome job so now they are ready to go back on.

The newly re-lined clutch shoes are now installed. Flywheel has been re-torqued to 15 lbs.

"Houston we have a problem...". I was about to put the oil pump assembly back together and noticed two cracks around the mounting bolts.
Every attempt to remove the old pump failed and it broke worse, I guess 46 years of old oil must have glued it in place.
Time to let it soak and somehow get it loosened up and replaced.

Time to drill and force the old pump out. This still took a long time...man was that in there tight.

Finally! Success! The old oil pump is no more.
After carefully rinsing out all the bits and pieces the inside was sanded clean for the new pump.
I'll have to flush the sump later just in case there is more stuff inside.

Replacement Oil Pump in place with new gaskets. Keep your fingers crossed that this one works good.

Oil pump cover/support bracket back in place with front motor mount installed.

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