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hatch project


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#126 derrin71

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Posted 15 February 2011 - 12:42 PM

Primered the engine bay this morning, came up pretty good.
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Next stop the floor, need to fill in a few unwanted holes, cut off a few unwanted brackets, make a RHS mufler hanger bracket and bash out a few dents from where someone tried to use the car as a 4WD. Then KBS the floor inside and out.

#127 _Kush_

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Posted 15 February 2011 - 02:06 PM

Mmmmm smooooth!
Lookin good, Derrin :)

#128 Mort

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Posted 15 February 2011 - 07:10 PM

When can i drop mine off to have the rust done :lol: , your doing some great work Derrin can't wait till it's finished.

#129 derrin71

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Posted 16 February 2011 - 09:26 AM

Rust repairs would incur an astronomical hourly rate (cash only of course) if i was even willing to do it, it's the worst job ever.
I don't know how Dirtbag and others do it all of the time.
Would drive me insane.

#130 Statler

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Posted 16 February 2011 - 09:41 AM

I have done the chassis rail mod on my hatch & had it passed by both the consulting engineer & D.O.T.

Just curious, but did you have the welds certified before you primed?

#131 derrin71

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Posted 16 February 2011 - 10:27 AM

My certifier is happy that as a qualified boilermaker and ticketed pressure vessel welder i know what i'm doing.

#132 _LS1 Hatch_

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Posted 16 February 2011 - 11:03 AM

Your firewall looks really nice all smoothed out like that!

I smoothed mine out some, but still have way more holes in it than you do :lol:

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#133 derrin71

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Posted 16 February 2011 - 11:08 AM

Your firewall looks really nice all smoothed out like that!

I smoothed mine out some, but still have way more holes in it than you do :lol:



I still have to drill a couple of holes right in the centre behind where the dizzy sits for the wiring to pass through. Only remembered after i finished yestereday!

#134 _LS1 Hatch_

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Posted 16 February 2011 - 11:32 AM

I know the feeling, I had almost forgot to drill the one in the center (above the pair of holes) and just remembered it when I had the red ready in hand to spray on, ha ha..

(it's for a vacuum line and the wiper motor harness...)

#135 Statler

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Posted 16 February 2011 - 12:32 PM

My certifier is happy that as a qualified boilermaker and ticketed pressure vessel welder i know what i'm doing.

That's pretty much the same response i got from dot. :spoton:

#136 derrin71

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Posted 04 March 2011 - 07:33 AM

Here's an update on what i've been doing lately.
Been working on tidying up underneath the car. Cutting off unwanted brackets, filling up unwanted holes etc.
The biggest job has been straightening up the chasis rails (both sides) that someone used as a jacking point.
I tried to straighten it up with heat and a slide hammer but didn't have much luck due to the 3/8" thick bar inside the rail. The easiest way seemed to be to cut the section out and replace it.
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Next to strip off the underside in prep for paint, Looking forward to that!

#137 _Kush_

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Posted 04 March 2011 - 09:26 AM

Nice work as always, Derrin
What's the thickness of the walls on those rails. 1.6 or 1.2 ??
I've got a few dents that I'll need to start on soon.

#138 derrin71

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Posted 06 March 2011 - 04:51 PM

I replaced it with some 1.6mm sheet i had laying around with the original flat bar stitch welded on the back. It may be a litle thicker than the original.

#139 derrin71

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Posted 23 March 2011 - 08:04 PM

Latest update, finished painting the underbody with KBS Rustseal. I am going to do the floor inside next with the same stuff.
The floor came up pretty good, i wasn't too worried about getting it perfectly smooth as i am going to finish all of the underside with body deadener before i paint the car.
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#140 derrin71

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Posted 02 April 2011 - 11:51 AM

Finished my latest round of rustproofing this morning.
Painted the floor inside with KBS Rustseal.

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Also filled in the bottom of the plenum and repared a piece of the plenum which had rusted,

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Covered the weld with seam sealer to mrevent any possible leaks and painted it with KBS as well.

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#141 derrin71

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Posted 10 May 2011 - 05:32 PM

Here's an update on what i've been up to lately.
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I have been getting stuck into the rust in the hatch area and as usual if you think you only have a little rust problem then you will be dissapointed when you strip everything back and have a look at what someone else has covered up with bog and brass.
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Here is the LH C-pillar repaired, i replaced the rusted inner section, rust converted everything inside, etch primed it and drilled a couple of drain holes inside the pillar as well.
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Also replaced a piece in the upper corner.
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And the lower corner.
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Cut this section out of the rear panel as it had been stoved in and about an inch of bog used to fill it, will be replaced with a straight section of steel.
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This area needed plenty of work as the section directly above the tail light also needed replacing.
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And one of the worst areas is below the chanel that holds the rubber along the rear panel, the easiest wat to tackle this will be to cut it all out and start again.

#142 _Kush_

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Posted 10 May 2011 - 06:22 PM

Excellent work, Derrin! :buttrock:
Did you have to make those repair sections yourself or can they be bought from the shop? I've got to do the same repairs :Headbang2:

#143 _Liam_

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Posted 10 May 2011 - 06:33 PM

Excellent work, Derrin! :buttrock:
Did you have to make those repair sections yourself or can they be bought from the shop? I've got to do the same repairs :Headbang2:


Shoulda bought a 4 door... :surrenderwave:

Nice work mate, as always.

#144 derrin71

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Posted 10 May 2011 - 08:21 PM

Have a look at the Rare Spares site, the outer c-pillar, upper and lower sections and the chanel which runs along the back are all available. (although they don't fit perfectly and require a little modification) I had to make up the inner c-pillar section where the rubber attaches and i will also make up the channel along the back and, the top piece of the rear panel which i have also cut off. A mate of mine owns an enginering shop with a guilotine and brake press so this stuff is pretty easy.

#145 derrin71

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Posted 18 May 2011 - 05:05 PM

Did a little more today,
Went down to my mate's shop and made up a couple of pieces i needed.
Replaced the section across the back first,
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Then i added the rubber channel and the section i had cut out which had been dented.
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Hopefully i should finish off the hatch area tomorrow.

#146 _Liam_

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Posted 18 May 2011 - 07:10 PM

Nice work Derrin. Looks the business. What's the next point to attack?

#147 derrin71

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Posted 18 May 2011 - 09:05 PM

Tomorrow i'm going to finish replacing a couple of sections in the drivers side c-pillar. Then i will smooth out all my work around the hatch area and start working my way around the car one panel at a time stripping the paint and repairing any areas i find. I will test fit the hanging panels as i go to make sure everything lines up properly. I know both of the doors have some rust in them hopefully not too bad. We will see how bad it really is when i strip them. As i finish an area i will prime it. The short term goal is to have it painted before the end of the year.

#148 derrin71

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Posted 27 May 2011 - 04:02 PM

Got a bit more done today.
Finished off smoothing out the c-pillar repairs and primered them.
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And stripped back the rear panel ready to be smoothed out.
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#149 derrin71

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Posted 05 June 2011 - 07:48 PM

I managed finish off the tailgate of my car today.
Smoothed out a few areas with filler.
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Then primered it.
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Next step, strip the hatch, repair any damge and get it ready to test fit to the body.

Edited by derrin71, 05 June 2011 - 07:49 PM.


#150 _Kush_

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Posted 05 June 2011 - 08:55 PM

Nice! :)

All you LX guys have got it too easy! You don't need to change the taillights! Hahaha! :)




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