The replacement boot floor cross member has cleaned up pretty well, but the end plates that are welded into the sides of the chassis were pretty bad. After several coats of Jenolite Rust Remover, cleaning back with a wire wheel and reviewing, I'm writing off both sides as too far gone. Other parts of the... Continue Reading →

Slowly working on putting repairs back in. The arch vents here were cleaned out and treated with Jenolite rust remover and primed up on both sides. Working on the drivers side at the moment because this is the better side. I have to keep reminding myself of that. Towards the front of the arch there... Continue Reading →

So the original boot floor in the Rallye is out. It looked like it had a load of bricks chucked in it at some point in the past and then was driven over a section of Belgian Roubaix at pace. It was a mess of dented and distorted metal to look at every time you... Continue Reading →

After a bit of searching I tracked down a pair of the boot floor reinforcement spars that some good soul has reproduced to a good quality. That'll save a chunk of time so well worth getting them. Took the car outside and with the rear bumper off, started to clean up the inner rear arches... Continue Reading →

Drilled the spot welds on these brackets out the back of the Rallye. A good chance to admire the quality of the paint and having sanded it to realise that the interior was painted white at some point in the past. Looking forward to sanding this handprinted mess off and getting the interior smooth again.... Continue Reading →

I imported a Polyvance plastic welder from the US - they do one with a European style plug which is fine as a I can use that with a European Style cable reel that I have. I bought it for doing a bumper repair on the Audi and as the wheel arch liners can't be... Continue Reading →

Other projects around the house and workshop keeping me busy but did manage a bit of progress... Painted up the catch tank and the coil pack brackets and fitted that back in.. Fitted those and then put in an insulated bulkhead fitting for the battery cable. In doing some further fettling, I came to the... Continue Reading →

Wanted to find a way to get the oil catch tank in. Spoke with Sandy Brown to confirm positioning. Didn't want to do something conventional above the gearbox mount so made this instead. CAD template design converted to mild steel Test fitment on the car Just needs a lick of paint...

Passenger door has always had check strap issues so decided to do something about that and treated the car to a brand new part. Comparison of old vs new and there are a few subtle differences... The result... https://www.youtube.com/watch?v=83PiL39fyrc?

Engine's swapped over time to cut the scuttle... Lots of marking up... Chopped the scuttle to create a letterbox for the bodies: Top down view The bulkhead face of the scuttle is shaped and for what I want to do I needed to smooth it so a bit of chopping and welding needed. With the... Continue Reading →

Footrest is in. It was a mission, but second time lucky on the welded in captive nut mountings. Should make it nice and easy if I decide to run carpet and gives me more confidence than the threaded rivet inserts. Powder coat is going to need to be re-done. It cracked and peeled off as... Continue Reading →