98 replies to this topic

[panelbeaterpeter]

It's been over a year since the last, so I figured an update might be an idea. Breaking up with my now ex Mrs, moving house, and a few other complications delayed things a little, this is what has happened since my last post.


Got a wing sorted, genuine new ones are too expensive and non gen ones don't fit, so decided to fix the old ones, starting with the better of the two.

This area was a bit crusty


Cut out


Made new one


And welded in




This bit was also a bit rough


Cut out and welded



Due to most 2CV wings seemingly doing this at the top of the arch;


...and generally being quite weak, I got some 4mm steel bar


And welded it round the inside lip


The difference in strength is amazing, so much more solid, feel like I could almost sit on it.

Repaired creased area




Blanked the side indicators, will relocate these somewhere else later.


A 5p did the job nicely



Thought I'd have a play with the front indicators, and get rid of the horrible big plastic ones.


Hole filled in




Cut out again..


Bent a bit..


More metal added..


And add some old Lucas 488 sidelights, fitted with amber bulbs.. Looks a bit more retro..


I also fitted new A panels, but lost the pics. Will post if I find them

Can't wait to do the next wing.. ¬_¬

Edited by panelbeaterpeter, 02 January 2013 - 08:08 PM.

[panelbeaterpeter]

Sourced a decent N/S/F wing as my old one was a bit past economical repair. A fix was doable, but I didn't want to do it!



Both front wings are now finished, with frenched indicators and underwiring..




Sourced a decent rear wing to replace mine that was very badly dented, and sorted them too..




I have also got the tailgate and lamp bar ready for primer, but no photos as they're shy.

Bulkhead is also sorted, this is the before shot, complete with stonechip underseal sound deadening stuff and a cracked battery box area



Bare metalled (I really enjoyed doing this)


Rusted and cracked battery box metal cut out and replaced


Wing mount and strengthening piece made and welded in


Etch primed

[panelbeaterpeter]

Last bit of rot was the Bonnet hinge/scuttle area. Seeing as this is an area most 2CV owners will need to fix at some point, I took detailed pics, hopefully will be of use to someone.

Started off with this


The first step was to drill out the spot welds on the lower lip


And remove the tabs at the ends, first by drilling out the spot welds


And then grinding the tab away, as it's brazed.


I bought the basic hinge repair section from ECAS, http://www.ecas2cvpa...ails-p-840.html
At £30 it's pretty good I reckon, much thicker gauge metal then standard Citroen and Galvanised, so it'll last for a few years.


I started by sitting it on the scuttle with the old hinge removed to mark the length


At this point I noticed the repair panel was higher than I wanted, so I cut it down silghtly to about 5mm down from the curve of the flap aperture


I then cut out the old panel, leaving a section at the top to be cut out later, this is so the repair panel can sit in the correct position before accurately marking the top for cutting.


I was glad to find out the inner scuttle was very sound. However the lip at the top of the bulkhead wasn't, so I chopped that bit out, and let in new metal.




I then lay the repair panel in place, marked, and cut the remaining metal out.


I also brushed thick hammerite inside the scuttle to keep it good for a while, and applied zinc primer to the underside of the new panel.


I then clamped the panel in place for welding. At this point I noticed that the curve of the area of above the hinge was too round, so I flattened it a bit in my folder. I could have fitted it as was, but it would have needed a bit more filler than I would have liked. I ground the galvanised coating off the edges of the new panel, as the fumes are bad for your elf, and it doesn't weld too well.


I started welding the panel in with tacks at intervals to keep the panel cool and avoid warpage, plug welding the bottom lip.


Carried on until it was welded solidly around.


And dressed with a flap wheel and 80 grit on the sander.


Followed by a skim of filler on any high or low sections, then a quick coat of primer to protect it from the elephants.




I also managed to get the drip rail completed on one side, I bought these sections from ECAS, http://www.ecas2cvpa...long-p-367.html they were much shorter than I expected, so I used them both on the one side.


Seeing as the rot was quite high up, I had to bend one of the sections, I think ECAS/SPOG assume that people will only be replacing the straight bit..



Before


And after



I shall order more for the other side, and once the N/S rail is done, that's all the welding on the body tub COMPLETE. Excitement all round.

[panelbeaterpeter]

So I got hold of a bonnet from a friend,


Makes the car look a bit like a car again! It also fitted on the hinge I had fitted, which was a bonus.

I first removed the sound deadening which was oily, heavy and generally a bit pointless.



Then I went about repairing the small areas of rust which were present. Firstly a new front edge was made and welded in, (no "before" pictures of this)



And then I cleaned up the inner hinge area which was a bit crusty.


Hinge cut and split from inner section


Inner cut out and replaced, with hinge repaired




Inside primed


Finished the drip rail on the N/S


Figured out and made a locking mechanism for the suicide door catches

Locked


Unlocked


Designed to match the release lever.


I then made and welded tabs on the B post side of the front doors, for attaching a check strap, as per the rear doors on a standard car.


Being a tight bastard, I decided to try and make 50's style bumpers.

Got this,


And shortened, narrowed and generally hacked it about, until it looked like this.


It looks a bit like an early example, but I'm not happy with it so if anyone wants it, let me know, will need brackets and over riders, some Neanderthal threw away the over riders :evil:

I then cleaned glue and foam and general gunk from the bulkhead areas, and inner side panel.





And prepped the interior metalwork for primer.


Followed by the outside.



I then flipped the shell, and etch primed the underside.


Followed by textured stonechip paint on the inner wings, and floors.





Then I primed the entire underside in a decent high build 2k primer.



I then gathered all the exterior panels together


Hung them up


And banged on more 2K HB primer.

[panelbeaterpeter]

Paint time. First I quickly flatted the primer, and sealed all the seams with wet on wet PU sealant.


Then on with the paint. It's a difficult colour to photograph accurately but it looks something like this. The finish isn't amazing as I didn't spend a huge amount of time on prep seeing as it's just the underside, but I like the colour! It's Citroen AC513, Vert Cactee.

[panelbeaterpeter]

So then I flipped the shell the conventional way up, and temporarily bolted it to the chassis so I could check alignment of the front panels before they go into paint.

Started with the lamp bar


Followed by the wings, bonnet, and "eyes".



I'm happy enough with the fit of the front end, the lamp bar was quite badly bent, so a bit of levering was required, and the edges of the A panels needed a tickle with a hammer to get the wings to butt up tight. Both wings are original Citroen which helps.



I also threw on the doors and rear wings to check fitment, all good there.


Then the chassis went back into storage and I masked up for primer to the top of the body tub.



And primed the body, headlamp bowls, seatbelt mount brackets, pedal box THINGY and wing valances

[panelbeaterpeter]

After a bit of prep.. (6hrs)










The colour looks different in every photo, this one taken on my phone is accurate to real life..



I also got both front wings and the underside of the bonnet painted.






Various exterior nuts and bolts


Vent shutter


Wing valances


Headlamp Bowls


Pedal box thingy, and seatbelt mount strengtheners


Outside of the bonnet


Also painted inside the rear wings, no photo of that.

All that remains of the body panels to paint are the doors and outside of the rear wings, I'll be doing the bumpers and lamp bar a different colour, probably satin finish grey.

[rally515]

great work on blending in the scuttle corner also got love for your new blinkers in the wing.

Great bit of metal working going on here (i take my hat off to you sir)

[minipete]

Simply Brilliant,you certainly are a master of your trade.When the old Dolly is put back together it will be so much better than when it left the production line.

[sonikk4]

What a transformation Pete and the colours look good. Very nice.

[leaky]

WOW cant believe it was a year since the last update. Looking great and love the colour choice!

[panelbeaterpeter]

Cheers, yep it doesn't feel like a year, that's for sure. I'm hoping to have it finished by May, so I need to pull my finger out..

[Marc_mcq]

Just read the full thread.... This looks incredible! Excellent work mate!

[steven]

just read this too amazing work and lovely paint !

[Gazza211]

Great to see a Master at work, attention to detail is just spectacular, must say the 2CV isn't really my cup of tea but the repairs, mods and the paint are all awesome, Can't wait to see it all back together.. Gaz