Well managed an hour tonight, looking forward to getting some quality time on this over the next few weeks. Seeing as I am going down the heated windscreen route and have stripped out the heater matrix and blower, there was another hole to fill in the bulkhead. Stitched the steering rack support whilst I was... 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 →
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 →
Update time! Well with holidays and a bit off a lengthy spell battling the N/S inner wing, there's finally some progress to report. First of all though I managed to pick up a S2 Rallye Gearbox Pinion and Crownwheel that is already prepped and ready for fitting to a Quaife ATB limited slip differential. This... Continue Reading →
Finally getting towards the end of the near side repairs. The final repair panel is now being welded onto the wheel arch side of the inner wing.
A few months ago I picked up some 3mm steel brackets that were surplus from a refurbishment of our office space. I think that they're used to mount door closure mechanisms or something similar. Anyway it turns out that they were nearly perfect to make good the repairs to the gearbox mount top plate. Chopped... 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 →
Rallye Project 