Little update as work slowly progresses. This is a rather complex shaped gusset that sits within the chassis rail acting as a support. It curves in all three axis. Mine was so rotten it had to come out and I fabricated this replacement out of sheet steel, it just needs finishing off and prepping for fitting.
I’ve also started shaping up the repair panels for the other sections removed, this is the main chassis rail side that will sit over the gusset above.
Finally this was the top of the chassis rail (i.e. the bit that you look down on when you look into the engine bay). The photo shows the underside of it that is internal to the chassis rail and you can see how much of the original galvanised coating is left. Worryingly it looked fine when it was in the car all painted up, but once the little bits of rust and bubbling paint was cleaned off both sides it was swiss-cheesed in many places.
Little bit more chopping needed to get rid of all the bad bits in the O/S wing and arch but I’m getting there. It’s just such slow work! Must have gone through about 20 of the Dremel cutoff discs yesterday working in hard to reach areas and they’re so bloody time consuming to have to stop and change.
Some one joked and asked if it would be ready for the French Car Show in 2011. I haven’t even started on the N/S of the car yet…
Rallye Project 
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