Update

Posted: 8th May 2017 by asteriskr in 106 Rallye S1 16v
Tags: , , , , , ,

Turned card templates into steel:

Rallye photo

End of the bulkhead was a bit ropey so marked it out and then cut a big bigger chasing the rust. This needed doing as you need to be able to weld this into the inner arch repairs.

Rallye photo

Rallye photo

Not too bad under the seam, only the end section nearest the arch needed some new metal in the lower part. Repaired with a patch panel.

Rallye photo

I’ve fabbed up a section to close up the wheel arch (took hours), but before I fit it I thought I’d check out the chassis rail a bit more closely because it didn’t look too clever. Also it gave more space to work in to assess things.

Rallye photo

Worse underneath in places…

Rallye photo

So chopped and drilled quite a bit and confirmed my suspicions. Several holes in the bottom of the rail. So all this came out. Some of which will be kept as a guide for making repair panels.

Rallye photo

This resulted in a large hole.

Rallye photo

There is more to come out but I need to put some new metal back in to try and keep some shape to it all before I chop out anymore.