Take lots of photos of where stuff is mounted, where pipes and cables are routed, etc. - I took a lot but still managed to miss some stuff which made reassembly harder than it might have been. Label everything you take off the car - down to the last nut and bolt. Bag stuff up. Label wiring connections.
I used the build manual linked to above and it was 95% there for my 1997 car.
On reassembly, if it doesn't need threadlock then use coppaslip!
Once you are down to a bare chassis then take it to Arch for them to strip, replace any really rusty bits, zinc phosphate prime and then powder coat. They will repanel it for you too - it's not worth reusing the old panels. Get them to powder coat all the suspension bits while you are at it - I didn't and regret it. They can replace all the bushes for you too - again I wish I had done this.
I had all my panels powder coated on the inside - this is personal preference but makes it easier to keep clean and should reduce the likelyhood of corrosion where panel meets chassis tube.
Clean everything that you take off - I didn't and it made reassembly a messier job and it wasn't nice having to bolt dirty/rusty bits back onto a shiny chassis.
Things to replace:
Clutch release bearing - use the Burton one described in low flying a couple of months back. Possibly replace the clutch if you don't intend taking the engine out again for a while.
Front lower damper mount bolts - and put plenty of coppaslip on them.
Brake hoses - convert the rears to flexible hoses while you are at it (I wish I had!)
Get the propshaft serviced and balanced (I can recommend Propshaft Services in Bradford).
Scuttle fixing channels - they will be rusted to pieces anyway but get the ones with the captive nuts for the windscreen - makes windscreen removal and refitting a doddle.
Once you get the chassis back from Arch then use Dinitrol (or Waxoyl) between the inner and outer panels, especially the gaps between the footwells and the side skins. They will leave some of the rivets out to help with this if you ask them.
If I think of anything else I'll post it up.
Yellow SL #32 - member of Drowned Rat Racing
Edited by - Shaun_E on 19 Aug 2010 08:46:31