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 →
So some significant progress over the weekend after 12 hours of further welding, grinding and prep work. Whole of the O/S inner wing and chassis rail is now in a POR15 base coat, it makes such a difference to the appearance and it's really lifted my spirits over the project. I've also modified by strut... Continue Reading →
Over the last week I managed to sneak in a few hours on the car and transformed cardboard templates into sheet steel and then formed it to the correct shape, drilled it and prepped it. With all the bends and unique qualities of this patch and probably because I tackled such a big section all... Continue Reading →
Fairly busy week and haven't made much progress. I did get some work done though - fitted a replacement section to the wishbone mount support. I'd had to chop this off to fit the repair panel on the chassis rail. Then rather than start on the inner wing repairs I decided that I would repair... Continue Reading →
After a little more prep work yesterday, the chassis rail top is now welded in place. Took my time carefully clamping it all in place and getting good contact for the plug welds and as a result I'm very happy with how it's turned out. Needed to get the dolly hammers out for one or... Continue Reading →
I'd been thinking that I didn't really want to swiss cheese the repair plate to be able to use clecos to hold it together whilst plug welding so here is the solution. Create some cleco washer plates, then drill the plug weld holes and the clecos can then still be used. Did a bit more... Continue Reading →
Managed another couple of hours tonight. Time was mostly spent getting things lined up with the clecos and fitting together. Need to spend some more time on making things fit properly then it'll be time to drill for plug welds and start putting it all back together.
After some use I have to say that the Tungsten Carbide die cutters are amazing. Even just used in the Dremel I'm not sure how I'd missed out on them this far but they have transformed my metal working. They're also going to save me a fortune in Dremel attachments. Jed was right with his... Continue Reading →
Following on from yesterday, I made the patch panel for the upper part of the bulkhead seam repair panel. Then prepared both faces of the joint with zinc etch primer. Once it was dry, marked the sections for the spotwelds and ground off the primer in the appropriate areas: Cleaned up the surrounding metal work... Continue Reading →
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 →
Rallye Project 