Chopped out the rot, put a 5mm alloy plate in behind the sound deadening to stop setting fire to anything and then tack welded in a repair panel. Fully welded it in, cleaned up the welds, primed and seam sealed just to be sure. One of the other things I've been cleaning up as I... Continue Reading →
When I was bleeding the offside brake calliper I noticed a patch in the front wheel arch that didn't look too wonderful so I scraped off the underseal to find it looking a little rotten underneath. So this weekend finally managed to find time to break out the tools and tidy it up! Chopped it... 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 →
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 →
About to become exceptinoally busy with work which will put a dampner on much progress in the coming month or so and as a result I am trying to make a bit of a push on the car. I suspect the biggest development is to finally decide the direction for the build, which is now... Continue Reading →
Well had a bit of time away and a chance to get perspective and decide what I wanted to do with the car. Came back with a bit more enthusiasm and then tonight managed to get a good few hours working on the car. Fabricated up some mounting points for the retaining straps that are... Continue Reading →
The more I looked at how other builders had fabricated mountings for fuel cells the more I decided that mine wasn't beefy enough so I have added in some additional sections to cross brace it with box section.
Found a bit of time to dress down the welds on the rear cross member and then weld on the final parts wihich are part of the reinforcements for the rear suspension mounts... Next step is to clean this section up and get it painted.
Rallye Project 