Managed to grind down the welds on the repair patch that I'd fittedm but not finished off on the last bit of work. Then the next tassk was making good the lower bulkhead lip that had been distorted by drilling the spotwelds and removing the rotten sections. Then the next sections to tackle were the... Continue Reading →
Finally managed to get the steering column and rack disconnected last night. Very easy in the end, it was just a job I'd been putting off. The rack unbolted without any drama and pedal box came out simply too. Fair bit of gunk and some algae lurking behind there so spend the rest of the... Continue Reading →
Really unproductive weekend. Probably managed 3 hours on the project... Chopped out some more rotten bits. I'm happy I've got to the bottom of the problem areas now, so started making up repair sections. When it's all put back together this section creates a water trap on top of the chassis rail. There was really... Continue Reading →
Looking ahead to some fabrication work I'm going to need to do, I've picked up this set of hole swagers from Colin Satchell. I labelled them up to make life easier...
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... Continue Reading →
Finally managed to get back to this. Having managed to get my hands on a sheet metal folder, I set about making the reinforcement gusset to sit inside the chassis rail. Starting point was a cardboard template which was transferred onto steel and shaped to give the initial shape. The chassis rail curves in the... Continue Reading →
I've been after one of these Air Temperature sensors for my loom for a while and finally Managed to track one down from Burton Power. It'll help the ECU trim the engine for variations in the weather.
Worked out what that row of spot welds were for... ... the internal chassis rail reinforcing gusset was very rotten though so chopped it out... Pretty much all of the roof of the rail which is thinner SWG20 is badly rotten - it actually went to holes as I cleaned it up with a twisted... Continue Reading →
I bought an 8mm spot weld drill bit through Frost not so long ago, but it's always been fairly poor at removing any of the spot welds on the car I've tried, so in the end I've given up and sourced this Wieländer and Schill 10mm bit... what a difference in terms of cutting power... Continue Reading →
Work on the car continues. Last night I cut a section out of the chassis rail to confirm the thickness (SWG16 / 1.6mm) and then popped out this morning before work to get a square metre of zintec of the correct thickness. I can't help thinking that anyone who believes that their 106 is rust... Continue Reading →
Repair panel welded in: Ground down and seam welds added in: Definitely a big learning curve ahead on this welding in repairs business! Next section for repair: The drawn cut lines were a bit freehand! Chopped: I'm not surprised it was rusty there was about 1mm of seam sealer between the panels in places so... Continue Reading →
So last back in 2008 when I first had the car I did some tidying up of the inner wing and essentially buried some pretty ropey metal work in filler. Today it was time to reveal the true extent of the rot! On a positive note the repair job had held up pretty well in... Continue Reading →
Rallye Project 