As you're all probably bored of looking at bodywork repairs on the 8v Rallye, I'll save you more photos until I get the job finished and then to a summary photo effort. Tonight I seam sealed the offside repairs tonight with POR15 seam sealer. Once that's set it's a case of using the self-etching primer,... Continue Reading →
Welding complete - I just need to dress the welds and prep for paint now. The photo's not so good but you get the idea.
My wife's a star and arranged for the in-laws to come around this afternoon to buy me some garage time. I didn't waste a second. Used the cardbaord template made yesterday to outline the repair piece and then cut it from Zintec. Started marking up for spot weld drillings and sections to form. Drilled first... Continue Reading →
So this is where I am up to with the repairs. To keep the panels in the right place when welding on the next section, it was time to crack out the cleco pins. They're a great bit of kit. Next job is the final repair panel. This is a tricky one but I'm going... Continue Reading →
Made some bits and welded them in: Haven't had much time available and phone's been playing up affecting photos - not sure how it is going from 40% battery to completely flat in two hours doing nothing but there we go. It probably didn't like the cold. The condensation has caused icycles to form under... Continue Reading →
As predicted more chopping out was needed, making the hole bigger! This is going to make me think carefully when I have to fabricate a repair section: The boot floor on this side is in A1 condition. I chopped a couple of sections from the seam that had started to pit and started the repairs... Continue Reading →
With the passenger side repairs under two coats of POR15 it was time to crack on with the drivers side which I knew was worse. I'll let the pictures do the talking: Needs some tidying up and I need to take a closer look at a few bits to work out if a little more... Continue Reading →
Cut about 5cm width out of the boot floor and welded in a new piece yesterday and finished welding repair sections in tonight. Just need to dress the welds and get it under some paint now. Boot floor from yesterday Wheel arch side plate Seam welded it from the boot side too for a little... Continue Reading →
After a summer of (occasional) use the Rallye was SORNed in autumn and has been hiding out in the garage. As I'm selling this one on this year, it was time to do a few little jobs before putting it in for a new MOT and getting it on the market. First job to sort... Continue Reading →
Following on from the end of the week, I fabricated up a wedge plate for the rear of the hydaulic handbrake mounting: Levelling wedge plate mocked up This is now welded in and in primer. Photos to follow at some point. The initial location for the brake bias valve which was to suit the braided... Continue Reading →
Managed a bit of progress towards getting the handbrake sorted. I have the same setup as jools is using on his car, which modifies the existing handbrake to drive the piston in the cylinder. First a bit of fabrication to create the pivot point from a bit of 1.6mm zintec sheet. Two halves welded together.... Continue Reading →
Well over the last week or so I have found bits of time to work on the dash, managing to reduce the weight by chopping out unnecessary bits, removing double skinned sections and hole sawing here and there. No where as near as Dean's attempts, but I do want it to look standard from the... Continue Reading →
Rallye Project 