Away from the rear quarter for a bit, I decided to swap the nearside section of the chassis rail, as you can see I've already done on the offside. Mainly as there are no gearbox mount holes
It's been patched, and not terribly nicely
so I've stuck a new section in. There's more welding to be done, but I was running out of time and I won't weld within 30 minutes of leaving the shed.
As I've started this front corner, I removed the repair that had been done to the floor / bulkhead / side panel. You can see from the sealant line on the side panel just how much overlap there was, and there's no paint on the new metal to stop it rusting between the two pieces.
First job is to rebuild the side panel, then the front end of the inner sill and bottom of the door pillar, then the bulkhead and finally (once I've done some more inner sill) the floor itself.
Its a shame I cut up a Firenza about 10yrs ago better than that which would have yielded some nice repair panels, couldnt give the shell away at the time!
I remember someone doing all the repair work on a coupe shell, then selling it for a few hundred quid after trying for a very long time. That was only a few years back, too. It's not as bad as my last project, in all honesty.
Its a shame now I have the space to store stuff big stuff like shells they dont come up often, makes me cringe when I think what ive chopped up over the years!
I've done a lot more on the front corner now - repaired the bottom of the bulkhead, replaced the front end of the inner sill and most of the bottom edge of it, so I thought I'd stick the floor in and stop debris getting into the chassis rail.
The welds still need to be ground back - I find I get a lot of flash rust forming on MIG welds if I don't paint it, so I've stuck something on it for now. I'll grind it down later, maybe when it's on the roll-over.
I've done a bit more on this now, first job was to remove the nearside rear wheelarch.
I then removed the last remaining part of the inner sill.
This didn't take as long as I thought it might - there are three short welds holding it to the body, the centre one was only connected to one side of the join and the other two came away with a bit of wiggling the panel forwards and backwards. It's thin steel, there is no paint on the inside and a lump of sealant to cover it all up.
Yesterday's job was to remove the rest of the bottom of the quarter panel to roughly where the replacement will be joined on.
Next, I'll scrape all that surface rust back and, as long as there's nothing that needs to be replaced on the inner structure, give it a good coat of Hydrate 80 while I have access. After that, I'll trim the replacement quarter panel so that I can clamp it in place to use as a reference to rebuild the edge of the inner wheelarch and the rest of the stuff it joins to.
I've made a bit more progress on this. Some Hydrate 80 applied, and then cut down the replacement rear quarter to allow me to test fit it and build the inner pieces to join it to the car.
Once the quarter fits roughly into place (it's from a 2-door saloon, so will need work around the rear end to make it fit) I have started with the closing piece between the boot floor and the bottom of the quarter, and the beginning of the inner wheelarch.
The drain hole is one of two extras to help get cavity wax in to the difficult-to-access parts of the shell, and to help the excess drain out afterwards. Scraped my head on a sticky-out bit of metal, so not in a good mood for the rest of the afternoon.
Post by grumpynorthener on Dec 2, 2021 13:51:02 GMT
Scraped my head on a sticky-out bit of metal, so not in a good mood for the rest of the afternoon
Ouch - Then again - I opened the main workshop door halfway last week to conserve heat whilst I quickly unloaded something from the car to the workshop - turned around and promptly boshed my head on the half open door
Yes, I've done that with the up-and-over garage door at home - leave it not fully open if it's raining so the rain doesn't flow into the garage, then forget a bit later. Funny, I've been remembering to wear my impact baseball cap this afternoon.
Deterioration is probably so slow you don't notice until you gat a new one.
That was certainly the case for me, although I have been using it for more than ten years. Ten new ones for £7.13 delivered, I'd link to it but it's been removed from eBay for some reason. I wonder how many years I'll eke out of this one before I finally weaken and use one of the other nine.
More has happened on this recently. I've removed the back panel and replaced the bottom half of it, so I can test-fit the outer back panel and the two quarters to see how they line up against the tailgate.
I've also removed the light boxes, had them blasted and repaired the holes
Now I'm just trying to summon up the courage to start welding the quarter panels on. There's no going back after this - I doubt I'll find more quarters if I mess this up. But I need to crack on with it as it's taking too long.
Offside rear quarter is now tacked into place along to top and front, and I'll do a double-check this afternoon before I do some of the plug welds along the bottom edge and arch as they're more difficult to remove if it has to come off again.
Offside rear quarter is now tacked into place along to top and front, and I'll do a double-check this afternoon before I do some of the plug welds along the bottom edge and arch as they're more difficult to remove if it has to come off again.
Nervous times but it wont do its self so as you say double check then crack on - hope it all goes well
I've been making a bit more progress on this, both rear quarters are now tacked into place and I'm test fitting the rear panel, which will hopefully go on this weekend.
Rear bumper test-fitted as an alignment check.
I've also sourced a much better driver's side door. I had intended (and still do intend) to repair this one, but a decent one will speed the job up. Once I've got that in place and checked the top of the sill against it, I can weld the back end together properly and get the bodyshell up on the rollover spit to finish off underneath.