Chassis Rail Work

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