Finished the brakes off tonight. Used a Gunson easy bleed system to push the fluid through the lines and it worked a treat. Used Dinitrol cavity wax inside the gusset repair sections, plugged them back up and painted the outsides with Gravitex. Will get some pictures of that posted up - shown here with the... 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 →
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 →
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 →
Near side chassis rail repairs complete. Need to stock up on a few supplies before further welding.
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 →
Rallye Project 