Managed a few hours in the garage over the last week. Primed the chassis rail gusset, cleaned, treated and primed the interior of the rail and today welded the gusset in. Also did some repair work on the metal where the chassis rail joins the cabin floor panel as it had been damaged when the... Continue Reading →
Some progress to report. Finished the chassis rail top and have it ready for fitting. It was a complex shape, but came together okay. Also finished work on the chassis rail gusset. Had managed to get the initial fold lines wrong and the original formed part was about 10mm too wide. Managed to reshape it... Continue Reading →
Managed a few more hours his afternoon on the car. Using cardboard I templated repairs sections for the internal chassis rail gusset and then the chassis rail top. I'll let the photos do the talking...
So after some careful planning, I chopped the engine bay side of the N/S chassis rail, carefully doing so to allow repairs without needing to setup a jig. There was plenty of structural rigidity in the sections of rail left and the rotten sections simply lifted out once they were cut out - once the... Continue Reading →
Earlier in the week I spent an hour in the garage and managed to cardboard template for the chassis rail side cut out, but spent most of my time sitting looking at it and trying to work out the plan of attack. The gearbox mount needs to come off to be able to repair the... Continue Reading →
This weekend I thought that I had finished the N/S inner arch repairs but as I welded on the last repair patch it has become obvious that part of the chassis rail was pretty rotten. What was supposed to be 1.6mm thick steel melted away under the tip like it was paper. It's a gutting... Continue Reading →
Finished the repair on the nearside inner wheel arch. I need to grind down and finish up these welds then seam weld this side of the engine bay. Then there's the repairs on the section where it joins onto the chassis rail, but the chassis rail shouldn't need any work. I also managed to pick... Continue Reading →
Made up this repair panel for the nearside inner wing during the week, just need to find time to weld it in now...
Been on holiday but back on the case now on the Rallye and onto the near side inner wing. It's no where near as bad as the off side, but still needs some attention. Can you see the swiss cheese? This is why it's rusted through. Chopped it out and started repairing - simple patches... Continue Reading →
The bumper mounts are now finished ready for fitting. Despite quite a lot of effort working on the cardboard templates, I'd misaligned the wing mounting hole with the nut welded to the back and also the lower bumper securing hole. This meant when they were tacked on they didn't align correctly. Rather than start from... Continue Reading →
Finally took some pictures of my modified top mounts to facilitate camber adjustment of the AST top mounts. Top mounts are in primer until I get around to repainting the whole engine bay. Non Power Steering Position. Power Steering Position.
Did a few bits and pieces over the weekend, but not a huge about on the car. I finally finished fabricating up a pair of bumper mounts to be welded onto the inner wings. The old ones were rusty and caked in filler. Quite pleased with how they turned out
Rallye Project 