435 replies to this topic

[derrin71]

Primered the engine bay this morning, came up pretty good.


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.

[Mort]

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

[derrin71]

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.

[Statler]

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?

[derrin71]

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

[derrin71]

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

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!

[Statler]

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.

[derrin71]

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.



Next to strip off the underside in prep for paint, Looking forward to that!

[derrin71]

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.

[derrin71]

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.

[derrin71]

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





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



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

[derrin71]

Here's an update on what i've been up to lately.

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.

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.

Also replaced a piece in the upper corner.


And the lower corner.

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.

This area needed plenty of work as the section directly above the tail light also needed replacing.

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.

[derrin71]

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.

[derrin71]

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,

Then i added the rubber channel and the section i had cut out which had been dented.

Hopefully i should finish off the hatch area tomorrow.

[derrin71]

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.

[derrin71]

Got a bit more done today.
Finished off smoothing out the c-pillar repairs and primered them.

And stripped back the rear panel ready to be smoothed out.

[derrin71]

I managed finish off the tailgate of my car today.
Smoothed out a few areas with filler.

Then primered it.

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.