948 replies to this topic

[Viktor]

Cheers guys. I wish I can take the car for MOT in the next couple of years!

 

The rear panel went in quickly yesterday, mainly because the car was already prepared and ready to receive the panel. I also checked other posts where the same job was done, so that gives you a clear understanding of what needs doing and the right sequence for it. Having a spot welder also helps a lot, if you are doing a resto like me you would need one. It is probably the best investment I have done for this project :)

 

Cheers.

 

Victor.

[Viktor]

Rear panel now completed.

 

Spot welded along the rear screen and the parcel shelf, including the bracket to fix the parcel shelf to the rear panel. That needed again higher settings on the spot welder due to the thickness of the metal.

 

 

 

Then after grinding the plug welds, I also applied some primer to protect the area from rust. A bit of filler and it should be completely seamless.

 

 

 

 

 

 

So that is the rear end done and dusted. 

 

 

 

More updates tomorrow.

 

Victor.

[MrBounce]

Cracking work again!

[stuart bowes]

yes mate looking good well done, bet that feels like a good bit of progress now 

[Viktor]

Cheers guys! Yes Stuart, I can see the light at the end of the tunnel... :)

[Viktor]

Not much done today, just assessed the situation for the other corner of the roof. I thought this side was in a better condition, but it looks like it is not!

 

The A-pillar is very rusted and with holes everywhere. There's also a hole on the roof as well.

 

 

 

Internally does look better than the other side, but still very rusty.

 

 

So first of all is to get the repair bits from the donor roof.

 

 

Now that it is out I can start separating the roof panel from the other bits. 

 

 

Will carry on tomorrow, but this repair is going to take a few weeks...

 

Victor.

[Viktor]

I started the roof repair today. This is how it looks...

 

 

 

Cleaning up and removing the old rusty metal.

 

 

 

Then I separated the roof panel from the rest of the pieces from the donor car, and cleaned the rest of the metal from the edge that will be welded to the car.

 

 

 

Then I separated the internal bits from the external, as this is what is going in first.

 

 

And to finish it off I applied some zinc primer in preparation for welding.

 

 

More tomorrow ;)

 

Victor.

[Viktor]

Today was mainly about cutting off old metal and getting ready for welding the new pieces in.

 

I started marking up the roof and cutting the old panel. I discovered an old repair, so cutting just after that so I can have fresh metal to weld into.

 

 

 

Then I drew the line and cut it off. Very rusted underneath as expected.

 

 

 

Next was to grind down the rest of the old roof panel along the gutter. I used the finger sander and lots of patience!

 

 

Then I cut the A-pillar internal bits, to leave room for the new bits from the donor roof (scary...). The gutter and the seam ensure the structural estability of the car, so keeping those untouched.

 

 

 

The idea is to replace the internal bits, to give the area more strength before removing the external bits. The roof repair will go in last.

 

More next weekend.

 

Cheers.

 

Victor.

 

Edited by Viktor, 16 April 2023 - 12:29 PM.

[colinf1]

Nice steady progress Victor, should be fairly solid and rust free next weekend!

[Viktor]

I got these panels from a very friendly chap near me. He put them on Facebook for free, so I couldn't resist! I'm still not sure what I'm going to do with them, perhaps for the next project?

 

 

The floor pans have a bit of surface rust, and the inner wings are for a clubman, but I think what it's left it will still fit my car. Shame I did my inner wings 2 years ago or so...

 

 

 

I also put some kurust on the roof that I'm half way repairing.

 

 

That was it for today.

 

Victor.

[Viktor]

Some more progress today.

 

First I applied some zinc primer to the whole area.

 

 

Then I fit the repair panel in position and clamped it to the car with everything I have...

 

 

 

 

Then I tacked it in place.

 

 

Then fully welded along the edge. I also added a reinforcement piece in the junction of both panel, and spot welded it.

 

 

After some grinding it looks a bit better.

 

 

 

And this is how it looks from underneath. It would need a bit more of fine grinding in the corner, but so far so good.

 

 

I also spot welded the other side, but forgot to take any photos.

 

More updates next week.

 

Victor.

[colinf1]

Going good Victor, making good progress!

[Viktor]

Some more work done today. I'm feeling a bit lazy this weekend, and also there's good weather so don't really want to spend time in the garage, but at least I put a couple of hours.

 

I started with this repair panel.

 

 

Cut it, cleaned it and tried on the car.

 

 

 

Then I marked up the lines to cut the old panel out.

 

 

And cut it.

 

 

All cleaned up and zinc primed.

 

 

 

Then clamped and spot welded along the windscreen arch.

 

 

 

And finally welded along the seam and on the right hand side. I didn't take a picture of the welding, just after grinding it down.

 

 

I still need to do the rest of the A-pillar, which is pretty rusted. That would need some fabrication.

 

Victor.

[MrBounce]

Excellent work again Victor - loving these updates!

[Viktor]

Thanks MrBounce!

 

I managed to complete the A-Pillar repair. It was quite a lot of work, but well worth it. Some photos of the process.

 

First cardboard template.

 

 

 

Next to fabricate the piece is metal.

 

 

 

Then, cut the old panel out. Lost of rust in there. 

 

 

The back panel is not too bad, so I cleaned it and put some zinc primer. I also grinded down the excess of metal along the seams.

 

 

I also added a reinforcement plate behind the area to give it some more strength. The gap will be welded later on.

 

 

I added a reinforcement plate on both internal sides of the A-Pillar and spot welded to the car. All zinc primed before, of course.

 

 

 

All prepared with zinc primer to receive the repair piece.

 

 

Repair panel clamped in place, and ready for spot welding along the seams.

 

 

 

All spot welded now. Looks a bit rough, but then I fixed the gaps with some welding and grinding.

 

 

 

I turned the car upside down, so I can weld the repair panel to the car.

 

 

 

And after a bit of grinding, it looks much better.

 

 

Some primer to finish it off.

 

 

I put the car back in position and finish the other bits.

 

 

 

 

That is the A-Pillar done. It should look better with a bit of filler, but I will do that before paint.

 

For tomorrow I'm hoping to finish the roof patch and then that should be the end of this roof corner repair.

 

Victor.