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 →
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 →
All finished today on the chassis rig. It needs a coat of paint at some point, but I've put it straight into service. It ain't pretty Shell went on with out any major problems just needed to slightly adjust the position on the mounting holes for the front supports where they tie onto the wishbone... 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 →
Baker BM have been doing an uprated gearbox mount for some time and a mounting for the engine for the first series Rallye, but the engine mount for the series two is new. I was down on the waiting list and mine came though in the post earlier today. They're called group N mounts, but... 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 →
Rallye Project 