Chassis Rail Work

Posted: 28th April 2017 by asteriskr in 106 Rallye S1 16v

On the inside of the car in the drivers footwell there was the tell tale sign of the seam being compromised with a hint of rust showing through the seam sealer. In the end chasing that out meant removing pretty much the entire seam. As part of cutting that rot out I did some more cleaning up on the chassis rail and found a hole:

Chassis rail repairs

In chopping the bad bit out of this section of the rail I cut through the small tabbed section in the centre of this photo. There was a spot weld onto it, but this bit was so corroded you couldn’t actually tell that. So a bit of extra careful cutting was needed to allow this replacement tab to be welded back on

Chassis rail repairs

Repair section in, cleaned up and primed

Chassis rail repairs

Next step for this weekend is to convert this CAD into a replacement section for the top of the chassis rail gusset panel.

Chassis rail repairs

Once that’s in I can get a get on with making good the original seam.

Inner Wing Repairs

Posted: 14th April 2017 by asteriskr in 106 Rallye S1 16v
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Main section of the inner wing now replaced.
Repairs

Some more patching happened.
Repairs

Repairs

The current entertainment is this:
Repairs

Repairs

Had some fun along the way. There are many seized bolts snapped in the captive nuts. Normally you’d be able to get them loose by welding a new nut on – by the time they get cherry red, they should come loose. I sheared three nuts off this one on the slam panel…

Repairs

…then this happened after I gave up and drilled it out.

Repairs

Wing Work

Posted: 31st March 2017 by asteriskr in 106 Rallye S1 16v
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Strut out and a bit of a tickle with a twisted knot wheel in the grinder to get the underseal off and the work needed is greater than originally thought.

Inner wing

Chop chop! The seam welds on the engine mount made it a bit harder… Needs a bit of a clean up and then some fresh metal can start going back in.

Inner wing

The O/S/F wheel kept going flat so whilst the strut was off I took a look at it and discovered that it’s had a big impact at some point and the inner bead seal has had it so I’ll get a tube put in that so at least moving the chassis around the workshop is a bit easier.

Offside Inner Front Arch

Posted: 26th March 2017 by asteriskr in 106 Rallye S1 16v
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So I looked at the offside front inner arch and knew that I couldn’t just leave it as it was. It wasn’t just the aesthetics, it looked structurally bad.

OSF Inner Arch

A little love from some 1mm cutting discs and we’re off…

OSF Inner Arch

Ermmm, there’s three layers of metal where the 16v engine mount has been added on when there should only be two.

OSF Inner Arch

That’d be that extra plate that was welded on then…

OSF Inner Arch

I’m seeing daylight through holes that shouldn’t be there and the bit around the grommet hole (particularly below it) is very ropey. Looks like I’ll be doing some more cutting and making a bigger repair patch…

Bonnet and Battery Tray

Posted: 19th March 2017 by asteriskr in 106 Rallye S1 16v
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Bonnet mod is finished:

Bonnet Mod

The other job was tidying up the battery tray which had been chopped and was bent outta shape. This is after I put a big adjustable spanner on it and got it pretty much straight:

Battery Tray

Bit of 1.5mm zintec and some shaping in a vice with a BFH, welded, finished and final shaping and it’s done. Another small job off the list.

Battery Tray