Managed to get the boot floor in a few weeks ago and eventually ground the welds and gave it a lick of primer. The butt weld where the new floor meets the old has had a skim of filler and it will need some tidying up in future.

Trimmed the carbon spare wheel tray to follow the curve in the back of the car. Did this with the boot panel in the car because the vertical upward face also needs to be taken into account whilst trimming. Whilst it was in the car, I drilled up from underneath to put the fixings in.... Continue Reading →

Some calculating, a couple of pilot holes to get the cuts in the right place and then started the work on the spot welds. Quite pleased with the spot weld removal, just needed a little bit of a tickle to clean off the remnants. Next up was a vertical cut to allow the cross member... Continue Reading →

So depressing day today. Lots of work will need to be redone, because I didn't take enough measurements along the way when reassembling. Here's the low down. Cut the repair panel out of the sheet. Very little fine tuning needed to get it to fit. Welded that in... Realised that I hadn't ground down the... Continue Reading →

So the last few weeks were spent repairing the replacement boot floor panel. There were several bits like this from where the breakers had extracted it from the donor shell with a big Skil saw. There was some need for repairs on the edge flange, but other than that it was in good shape, just... Continue Reading →

After about 10 treatments with Jenolite rust remover and a lot of work with various wire wheel attachments the boot floor cross member was primed up last weekend: I've also finished repairing the main repair panel for the off-side inner rear arch. It'll get cut up to fit down the line but it's been easier... Continue Reading →

Visited the timber yard and picked up a 300mm length of hardwood sill to used as a form. Routed it out and started working it with a hammer and dolly. Little bit of of tidying up and it's looking pretty close. Chopped the exhaust hanger off, cleaned it up and transferred it across. Primed up... Continue Reading →

Prepped the cross member end piece for the near-side and the chassis and tacked that in. I took the rear seatbelt anchor point brackets off the back of the rear seat hollow. They won't be needed in the final build and they're just a rust trap. Just in case I welded covers over the original mounting... Continue Reading →

Drilled and cleco pinned the cross member and end plates to get ready for fitting. Cut and after lots of measuring and aligning, tacked in the off side cross member end plate. The nearside is going to be much more difficult. The rot on the nearside is pretty remarkable. I have never seen rust jacking... Continue Reading →

Did a bit of CAD and then transferred to Zintec to cut out the repair panel: Used the same hardwood form and metal rods to press in the dimple: Came out okay, it'll need a bit of chopping down to get it to fit but the length is right: Also repaired the corresponding end of... Continue Reading →

The replacement boot floor cross member has cleaned up pretty well, but the end plates that are welded into the sides of the chassis were pretty bad. After several coats of Jenolite Rust Remover, cleaning back with a wire wheel and reviewing, I'm writing off both sides as too far gone. Other parts of the... Continue Reading →

Slowly working on putting repairs back in. The arch vents here were cleaned out and treated with Jenolite rust remover and primed up on both sides. Working on the drivers side at the moment because this is the better side. I have to keep reminding myself of that. Towards the front of the arch there... Continue Reading →