Very little done today. Managed to top coat the calipers and seam seal the N/S gusset repair section - tie coat primer goes on both side tomorrow. One of the orders I am waiting for contains the proper plugs for the gussets as I am missing some and don't have enough to put it all... Continue Reading →
Yesterday with the chassis rail and gusset repair section for the near side ready, welded the repair section on and then prepped it for paint. Prepped Fitted Also seam sealed the O/S section that had previously been POR'd. Not pretty, but no one is going to see it once it's covered in Gravitex and painted.... Continue Reading →
Yesterday ground down the repairs on the chassis rail leg and put it into primer (laid down a second coat tonight). Then cracked on with repairing the chassis rail gusset, making up a repair template out of cardboard - the gaffer tape is a structural element 😉 It's a lot easier making corrections in cardboard... Continue Reading →
Right progress from the last few days. N/S chassis rail section in primer. Fabricated up a repair section for the chassis rail. Utter, utter bastard complex shape to get right, but made it spot on in the end. Removed the passenger seat, lifted the carpet and moved the fuel line out of the way and... Continue Reading →
Finally went through the paperwork for the car today and discovered that in 2007 it had an MOT advisory on the chassis rail gusset on the near side. Kind of wish one of the previous owners had tackled it before it came as bad as it is now. Crushed metal, underseal and regular exposure to... Continue Reading →
Finished the offside repair tonight by welding in the gusset repair section. Tricky section to fabricate, but luckily I had carefully removed the original damaged gusset so could use that as a guide. Then ground down the welds. For reference swaging the holes is important for getting the plugs to fit in correctly... Over the... Continue Reading →
No updates for a few days. but that doesn't mean no progress. Decided yesterday that a bit more needed chopping out: Cleaned it up with a wire wheel and etch primed it. Started making a chassis rail repair section. Utter PITA having to go under the car everytime and adjustment was made to make sure... Continue Reading →
With the 16v shell laid up, it's time to tackle the work on the 8v road car - so first job! Tackle those two chassis rail gussets that are goosed. Off side gets the treatment first. So here the progress so far. Car's now up on axle stands... Initial Inspection: Pick off the loose underseal:... Continue Reading →
I've been cheesed off with not having a nice run around whilst the work is being done on the project car, so I've been on the look out for a run around. I considered all sorts including an Audi A4 Quattro Sport, but in the end decided to keep with something that will be cheaper... Continue Reading →
So after many years of happy ownership, a few speeding tickets, quite a bit of fettling (like that time the ignition key was stuck in the rear book lock at a 24hr mountain bike race) and some great driving, I've decided it's time to sell the Rallye. New job, more disposable income, I fancy an... Continue Reading →
Turns out that the Rallye is a great vehicle for getting to the Mountain Bike races. Over the years it's done it's duties getting various buddies to the race venues around the country. This weekend just gone it was the SAAB Salomon Mountain Mayhem at Eastnor Castle in the Malverns.
The M62 out of Manchester claimed the stock exhaust today. The back box dropped off at 70mph on the inside lane. The car without it is rather loud. Time for a stainless steel Peugeot Sport exhaust.
Rallye Project 