One day into the restoration, the £250 Watsonian already started explaining itself. The image below, I should explain, is not the finished article, but the template.
The trouble with bringing home an old sidecar is that it does not remain merely an old sidecar for long. Yesterday it was a faded black Watsonian Monza which Hay thought looked like the first car from a Big Dipper I was planning to build in the back garden.
Her sister thinks I'm building a bobsleigh for the Old Sodbury bobsleigh team, who intend to compete in the next Winter Olympics.
Today it has become an archaeological excavation, a structural investigation and, inevitably, a design exercise. I have barely had it 48 hours.
The first job was simply to establish what I had actually bought. Once the body and chassis were separated and the accumulated Yorkshire weather began coming off, the answer was encouraging.
The chassis has been smothered in underseal. Normally that can mean either somebody was trying to preserve the steel or somebody was trying to hide it. In this case, the frame appears solid. There is some pitting, but nothing which suggests it is quietly turning into lace.
The underseal can come off, the metal can be cleaned and inspected, and the frame can then be properly primed and painted. I had briefly considered polishing part of the front rail back to bare steel and lacquering it, although that may depend on what remains after 60 years of corrosion and enthusiasm.
The front bumper rail is another matter.
After scraping the paint from the joints between the front rail and the rest of the chassis, I found a distinct golden fillet. That is a strong indication that the rail was brazed rather than welded, which would be entirely consistent with British tubular construction in the 1960s.
This is unexpectedly helpful. A brazed joint can be reheated until the bronze filler melts while the parent steel remains solid. With the chassis properly supported, the original front rail should therefore be removable without cutting into or shortening the side rails.
That would make fitting a polished stainless replacement considerably easier. The old rail can be withdrawn, the joints cleaned and suitable sockets or spigots fitted to accept a removable stainless front section, retained by discreet bolts or pins. It would be removable, replaceable and easier to polish.
This is the sort of thing which begins as a way of avoiding unnecessary expense and ends with an ex-navigating officer commissioning a bespoke stainless component because he did not want to spend unnecessary money.
The wheel presented a similar temptation.
The tyre is a Continental 4.00-10, and the seller described the wheel as a Mini wheel. The 4 hub studs, however, are on a 3¼-inch pitch circle, which is not a standard Mini fitting. A bespoke 10-inch wire wheel could be made, provided I wished to spend somewhere around £700 improving a £250 sidecar.
I do not.
The existing wheel and hub will therefore remain. They can be rebuilt, cleaned and painted, perhaps with a polished hubcap or some other modest embellishment which suggests period engineering without drifting into plastic imitation wire-wheel trims from a child’s pedal car. Watsonian have a suitable hubcap for £99.99.
The interior was less encouraging.
It is black, rough, knobbly and deeply uninviting. It looks less like somewhere to carry a passenger than somewhere local authorities used to store grit.
I initially considered smoothing it with filler, but the body will flex and filler has a habit of responding to movement by cracking in public. Upholstered panels would improve it, but they would also add weight and provide damp with somewhere private to settle.
The more sensible solution may be simpler.
I have a considerable quantity of grey industrial floor paint left over from the garage. It is tough, repels almost everything and is not very far removed from the colour of the Virago. More importantly, it would stop the interior looking aggressively funereal.
There, that's better.
A removable rubber mat can cover the floor. Thin coloured plastic panels could be fitted to the sides like door cards, using lightweight trim fixings rather than building an entire drawing room inside it.
That would conceal the worst of the original moulding, add very little weight and remain removable if water gets behind it.
Because water will get behind it. This is Britain.
The floor construction initially caused some confusion.
At first, patches of exposed wood made it look as though the plywood formed the entire floor. Then it appeared to be sitting in a recess in the GRP. Then it became clear that the plywood is supported by the moulded fibreglass recess and glassed over from inside, apart from a small damaged area where the covering laminate had broken away and exposed the timber.
The plywood itself appears remarkably sound.
It has lasted since the 1960s with little more than red primer and black paint on the underside. I have stripped that underside back to bare wood and see no reason to entomb it permanently in resin.
The plywood supports the tub and should remain visible and accessible. One day, perhaps around 2086, somebody may need to replace it. It would be discourteous to make them excavate it from beneath half an inch of modern composite material simply because I had bought resin in bulk.
I will prime it with an exterior wood primer and finish it with the same industrial floor paint. It will be sealed, protected and still readable.
The original arrangement lasted about 60 years with considerably less sophisticated protection, which is a fairly persuasive product test.
I have already repaired several rips in the GRP and reinforced the moulded recess which supports the plywood base. The plywood was sound, but parts of the surrounding fibreglass had split and were plainly doing rather less supporting than Watsonian originally intended.
That has now been dealt with using fresh glass cloth and resin, extending the reinforcement beyond the damaged sections rather than merely sticking the tears back together and hoping they would forget what happened.
It is not glamorous work, but it has clarified the construction. The plywood carries the floor loads, while the GRP recess locates and supports it around the perimeter.
Strengthening that junction should prevent the old cracks simply reappearing a few inches further along, which is fibreglass’s preferred response to a purely cosmetic repair.
The 3 seized bolts near the front were rather less cooperative. They passed through the plywood and secure the remains of a substantial steel bracket inside the footwell. It has rusted away at the bend, which initially made the whole arrangement seem perverse. Why put the steel inside the tub rather than underneath, where it could support the floor?
The answer became clearer as the construction revealed itself.
The bracket performs 2 separate functions. Its upper half forms part of the sidecar’s attachment system. The lower connection ties it to the sidecar chassis, while the upper connection carries the link onwards to the motorcycle. Both are reached from inside the tub.
This is the upper half as you can see where it has rusted away from the rest.
The lower half did something different. It continued down the side of the footwell, turned across the floor, rose again to meet the other side and the corresponding chassis fixing pass-through. It was secured by those 3 bolts through the plywood. Essentially a large U.
Watsonian had therefore combined the motorcycle attachment and the front body mounting in one large and rather complicated piece of steel.
One option would be to reconstruct the broken bracket temporarily, using cardboard or a bent welding rod to establish its original shape, and then have a complete replacement fabricated. That would preserve the factory arrangement, but probably at considerable cost.
The more elegant solution is to separate the 2 jobs. The surviving upper section can be cut back and faired neatly at the break, leaving it to connect the motorcycle to the sidecar chassis. A new transverse cradle can then run across the front of the chassis beneath the floor, supporting the tub in much the same way as the existing support at the rear.
There is one remaining qualification. The vanished lower section probably prevented the upper bracket from pivoting around its lower chassis connection. I will therefore probably jst fabricate a bridging piece that replaces the rotted bend and attaches to sound metal on each half of the bracket.
The bolts have had roughly 60 years to become emotionally attached to the remains of the bracket and now refuse to turn. They will probably have to be cut or ground off, carefully, without setting fire to the plywood or converting the surrounding fibreglass into airborne misery.
Anyway, after trying to extract the bracket from its fibreglass shroud, it quickly became clear it was rusted to hell and beyond repair, so the entire thing will have to be fabricated. I'll probably make it in 2 parts for ease of fitment, joining the two halves with an overlap before encasing it in fibreglass.
The problem was hardly unique to Watsonian. Lotus was wrestling with much the same issue in its early fibreglass cars - how to put serious loads into GRP without crushing or cracking it. The answer was broadly the same: let the fibreglass provide the shape, and put steel reinforcement wherever the loads actually enter the structure.
While smoothing the area around the footrest, I discovered what appeared to be a small brass identification plaque. Unfortunately, I discovered it by removing some of the writing. This was not my finest archaeological moment. Fortunately, enough survived to reveal the number S-83. The S prefix dates the body to 1965, making it a Mk2 Monza, and 83 appears to be its individual production number.
I have photographed it and will now leave it alone. Further restoration might improve it to the point where nothing remains.
The nose trim has gone rather better. The Watsonian badge was discoloured, its mounting boss was ruined and the aluminium spear beneath it was bent and tired.
The spear has been straightened, cleaned and lacquered. The badge has been restored and painted. The missing boss has been replaced with a jam jar lid. This sounds less impressive written down than it looks. Once lacquered and fitted, the lid no longer resembles anything which once contained marmalade. It looks like a proper pressed mounting boss.
Restoration is partly engineering and partly ensuring nobody can identify the household packaging involved.
The screen is unlikely to survive. It shows signs of having been heated and bent into shape when it was made, and the cut lines are not particularly true. Replicating it from polycarbonate would be possible, but cutting a large curved screen neatly is not as easy as the internet pretends.
More importantly, I am not sure I want it. Even if I replicated it, to look original I'd need to source or make an aluminium surround. Much too faffy.
A Brooklands aero screen would suit the Monza rather better and give it a more purposeful appearance. I could build up the front edge of the cockpit with sculpted expanded foam and fibreglass, creating a low scuttle into which the screen could be properly mounted. It may not even require building up.
And because I have already made burr-walnut dashboards for the GT6, I am now considering making one for the sidecar. It need not be entirely dummy. A shallow walnut panel could contain a clock, a GPS speedometer and a USB charging port. The passenger would then know the time, how fast they were travelling and precisely how much battery remained while having no influence whatsoever over any of it. A discreet grab handle beneath it might also be useful, particularly once the GPS speedometer begins confirming what the passenger already suspects. Below is the ChatGPT mock-up, although the image on the lower right needs some consideration about the angle of lean.
It'll probably end up looking like a 3 wheeler Morgan, on 1 wheel.
Then there's the paint, which in places like it was done with Tesco's black eggshell, with a stippling brush. That all needs laborious rubbing down before filler is applied to imperfections, and rubbed down again. Lots of rubbing down - and then some high build primer, and more rubbing down.
The original seat is still in Barnsley because I forgot to put it in the van. This may also prove fortunate.
I had already found a £27 reproduction Eames DSW-style plastic stool which looked roughly the right shape to use as a former for a low-backed fibreglass seat. Since then, I have found 4 of them on Facebook Marketplace for £40, which gives me 4 separate chances to cock it up before having to admit the idea was flawed in the first place. However, it's worth a try in order to get something more ergonomic than a couple of padded boards.
The white shells are about 2.5 cm too wide at the bottom for the Monza cockpit, so they will require some surgery before they can be used as formers. That is not necessarily a problem. Cutting, narrowing and reshaping one is rather the point, and I now have 3 spares waiting to learn from the first one’s mistakes. If it works, forgetting the original seat after a 6-hour round trip will cease to be absent-mindedness and become an early design decision supported by bulk purchasing.
So, after two days, the sidecar has acquired a known age, a restored badge, a grey interior, a jam jar component and several competing plans for its future. The chassis is better than expected. The plywood is sound. The damaged fibreglass is already being repaired. The missing ironmongery can be made.
The interior needs rescuing from blackness, the front rail needs rethinking, and the screen may be replaced by something Watsonian never fitted but perhaps should have.
It is still, according to Hay, the first car from a fairground ride. But it is now a 1965 Watsonian Monza Mk2, serial number S-83.
That sounds much more respectable - even with a jam jar lid on the front.









































