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...
Another Weekend Gone
Further Repairs
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 →
Progress
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 →
Update
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 →
Progress
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 →
Repairs
Made up this repair panel for the nearside inner wing during the week, just need to find time to weld it in now...
Back On It
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 →
Bumper Mounts
The bumper mounts are now finished ready for fitting. Despite quite a lot of effort working on the cardboard templates, I'd misaligned the wing mounting hole with the nut welded to the back and also the lower bumper securing hole. This meant when they were tacked on they didn't align correctly. Rather than start from... Continue Reading →
Progress
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 →
Nearly There
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 →
Busy Day Today
Did some more tidying up of welds and then cracked on with something I've been meaning to do for a while, reinforce the wishbone mounting points. I had been lucky enough to be given a piece of 3mm angle iron which I've chopped and modified into reinforcement brackets. These took ages, but just need to... Continue Reading →
Patching Continues
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 →
Rallye Project 