Carlton Diamond Estate

You and me both!! 

Scuttle side panel had similar rust issues as the other side


Chunk chopped out


Weldy grindy action gives me this


Bottom end below the a post/sill/kick panel looked a bit manky


Chunk chopped out to see whats going on, I do have a full genuine sill to put on when the time comes, thats not too bad inside


The other side of the panel wasnt so good, really pitted and holed in a few places, wasted ages trying to save it with various chemicals


Another repair piece from the donor will do the job


Done and dusted

Thanks very much, your doing a grand job with your project, lets see who gets to the finish line first 

The outrigger/jacking point thingy had to be reused, I thought I had a new one but it turned out to be for an Omega B which means it was too short to use, The old one had really been pummelled over the years with misplaced jacking but I managed to get some shape back into it



A bit of not too pretty reinforcing to make sure it hopefully doesnt get squished again, you dont see any of this when its fitted!


Stuck in place forever

Onto the windscreen lower scuttle area, I think its had 3 screens in its 380,000 miles and as usual the paint gets damaged when the screens are replaced
Oh yeah thats what were talking about! where the rust had expanded it had actually put a split up the screen


The panel curves both ways so a bit of creative MDF tooling gets is this



Out with the old and in with the new



Unfortunately the ends havent fared that well, so more MDF tooling to get some shapes





and stuck in place, the ends just seem to float with origionally a load of sealing goo pumped in so thats what its going to get
the wiper linkage mounting brackets were also reinstated



Stuck on a decent coat of primer and some rattle can top coat just seal the primer now the weather is turning damp
Still lots of pitting where the rust was cleaned out but this can be dealt with once the final paint procedure has been decided

A bit of bling to get the mojo going, the origional dual mass flywheel was showing its 380,000 miles and nothing is available so we got this lump! just got to source a clutch plate as it will need to be sprung differently, im way off needing it but its here now!

Thats the idea! its a long ways off yet and might need to up the idle speed a bit but we will see how it goes 

Which Epoxy are you using?

I'm going to need some soon. Over on the Mig Welding forum Jotun is the go to brand. They do a Zinc loaded one I'm leaning towards at the moment, at least for underside and unseen areas.

Great progress being made here.

Sean

Got to start working backwards now, been putting this bit of floor off for a while


Underside view, there is a crossmember that joins to the inner sill which doesnt look too clever, I could just pretend I didnt see it and slather it in something but it will just come back to haunt me!


Off with the sill then so we can see inside, many spotwelds later



Its off, looks amazingly good inside with a heavy coat of wax and a coating of grime


Released the flange and 1st go at a clean up, should come up ok without too much major work