Posts Tagged ‘Rail’

8v Nearly Ready

Posted: 9th September 2011 by asteriskr in Rallye 8v
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Finished the brakes off tonight. Used a Gunson easy bleed system to push the fluid through the lines and it worked a treat.

Brakes Finished

Used Dinitrol cavity wax inside the gusset repair sections, plugged them back up and painted the outsides with Gravitex. Will get some pictures of that posted up – shown here with the POR15 Tie Coat Primer on. Next thing is to top coat in Hammerite white and then put the ARB back on. After that it’s back on wheels.

O/S Chassis Rail Gusset in Tie Coat Primer

Talking of which, I finished painting the Michelin steel wheels centre caps during the week.

Steelie Center Caps

Tonight I used a crow bar to prise to the inserts that were in two of the wheels to suit the VTR wheel bolts. Rear wheels are now on.

8v Progress

Posted: 2nd September 2011 by asteriskr in Rallye 8v
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Yesterday with the chassis rail and gusset repair section for the near side ready, welded the repair section on and then prepped it for paint. Put two coats of POR15 on tonight.

Repairs

Repairs

Repairs

Also seam sealed the O/S section that had previously been POR’d. Not pretty, but no one is going to see it once it’s covered in Gravitex and painted.

Repairs

Another one of my recent eBay bargains. A full set of hub covers for the steelies for £5 delivered. They were misspelt in the listing as Peugot van parts for a Partner van. They’re in amazing condition, so I wonder if they’ve ever been used. I’m going to paint the emblem and circular logo lip in silver like I did with the last set.

Repairs

Finally as none of the three parcels of parts that I have been waiting for arrived I decided to tackle a job which was more of a [I]nice to get done[/I] rather than essential. The front brakes need new discs and pads and the brakes off the 16v project car are ideal as they had done less than 500 miles since fitting. I’ve prepped the standard ATE callipers off the 16v ready for enamelling.

Repairs

I have some Goodridge braided lines to fit which should improve things a little – the brakes were a bit spongey but this may be more to do with the fluid probably needs changing as part of the service (doesn’t seem to have been done in any of the history I have for the car.

8v Repairs Update

Posted: 29th August 2011 by asteriskr in Rallye 8v
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Right progress from the last few days. N/S chassis rail section in primer.

Repairs

Fabricated up a repair section for the chassis rail. Utter, utter bastard complex shape to get right, but made it spot on in the end.

Repairs

Removed the passenger seat, lifted the carpet and moved the fuel line out of the way and away from any heat. Unfortunately found wet bulkhead soundproofing so I suspect that the heater matrix is shagged or there is a leaky connection in there somewhere. Dash needs to come out anyway for some other work, but another job to add to the list.

Chassis rail repair section welded into place – just need to grind down the welds now.

Repairs

Started repairing the chassis rail gusset section. Quite tricky this as you need to maintain the shape of the original as the repair sections are added in.

Repairs

I sourced a full set of Michelin steels this weekend, ordered essentials for servicing the engine and now just need a few bits and bobs to get the car ready for the MOT.

8v Near Side Repairs Commence

Posted: 27th August 2011 by asteriskr in Rallye 8v
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Finally went through the paperwork for the car today and discovered that in 2007 it had an MOT advisory on the chassis rail gusset on the near side. Kind of wish one of the previous owners had tackled it before it came as bad as it is now. Crushed metal, underseal and regular exposure to water and salt is recipe for bodywork disaster. Here’s why:

Initial inspection
Repairs

Picked off the loose underseal
Repairs

Twisted knot brush on the angle grinder started to reveal the extent of the rot
Repairs

Started cutting out the rot, but only revealed more problems
Repairs

Decided that it was easier to reconstruct the chassis rail gusset off the car so removed the whole panel. It also allowed me to properly chop out the rot from the chassis rail itself. All cleaned up and sprayed in etch primer tonight last thing.
Repairs

Next jobs are to fabricate up the repair sections and get them welded back onto the car. No way it would have passed the MOT this year without this issue being addressed. To be honest I am amazed it passed in 2009 (last test the car went through).

8v Repairs

Posted: 21st August 2011 by asteriskr in Rallye 8v
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With the 16v shell laid up, it’s time to tackle the work on the 8v road car – so first job! Tackle those two chassis rail gussets that are goosed. Off side gets the treatment first. So here the progress so far. Car’s now up on axle stands…

Initial Inspection:
chassis repairs

Pick off the loose underseal:
chassis repairs

Wire brush the rest with a twisted knot brush on the angle grinder:
chassis repairs

Had to take the ARB off at this point, but it didn’t want to leave the two drop links. I managed to loosen the nuts on the threads, but couldn’t get them completely off. The hex head fixings in the bottom of the drop links are made of cheese, so I had to cut the drop links off with a slit disc.

Cut off the chassis rail gusset
chassis repairs

Then cut out the rotten section of the chassis rail itself
chassis repairs

That’s it for today.

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