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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Jul 28, 2018 2:28 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Nasty splash panel. Typical of the standard of previous repairs
Attachment:
SDC13308.jpg
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At least this will be just about the simplest piece of fabrication I have to do.
Repair panel cut out, and used an old filler tin to form the curve
Attachment:
SDC13309.jpg
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Before I could start welding the heavens opened, so had to quickly pack everything away


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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Aug 12, 2018 2:12 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Just before heading up to Derbyshire for a few days to see family, and picking up a load of useful spares on the way (thanks Paul), I finished repairing the splash panel
Attachment:
SDC13311.jpg
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Just got the passenger side sills to sort out now, so it feels like we're entering the home straight of fabrication
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SDC13312.jpg
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The MOT tester clearly couldn't find his corrosion assessment tool the day he passed this :park:
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SDC13319.jpg
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This is about as bad as the drivers side, but having done it once, it doesn't worry me


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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Aug 13, 2018 4:40 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
If you have ever wondered whether a V4 bonnet will fit in the back of a c900...
Attachment:
SDC13318.jpg
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...Just, with the help of an assistant. There's also a mountain bike under that white cover, and still enough space for a 96 boot-lid.
Back to the job in hand
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SDC13320.jpg
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The repair section has 'SILL' written on it because I'm running short of steel and was working out whether I have enough left for the remaining repairs
Attachment:
SDC13322.jpg
SDC13322.jpg [ 242.24 KiB | Viewed 938 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:11 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
There were a couple of weeks in August when I didn't get anything done on the car, but last week was pretty productive.
Where the sills meet the floor there have been plates welded to the inside and the outside and the rust left to fester in between, as I have come to expect on this car :wall:
Attachment:
SDC13323.jpg
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Cardboard template is to get the angle between the sill and floor correct
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SDC13326.jpg
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Front section done
Attachment:
SDC13340.jpg
SDC13340.jpg [ 148.51 KiB | Viewed 756 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:18 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Forgot to take a picture with the middle section cut out
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SDC13342.jpg
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Attachment:
SDC13325.jpg
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Rust this bad so close to both the suspension mount and seatbelt mount could have been disastrous
Attachment:
SDC13328.jpg
SDC13328.jpg [ 203.9 KiB | Viewed 756 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:28 pm 
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Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
This was a really tricky panel to form and make a snug fit, due to all the different angles and heights involved
Attachment:
SDC13329.jpg
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Welded in, but only partly dressed
Attachment:
SDC13341.jpg
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The rear of near vertical outer section of the sill was pretty rusty too - viewed from underneath
Attachment:
SDC13331.jpg
SDC13331.jpg [ 122.91 KiB | Viewed 753 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:36 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
The bottom of the rear quarter panel, where it joins the has some previous welding which was quite nasty, so that also got chopped out (photo taken after sill repair)
Attachment:
SDC13337.jpg
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New panel formed and the inside given a coat of weld through zinc primer - also used on the sill that it will be welded
Attachment:
SDC13338.jpg
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...and welded in
Attachment:
SDC13339.jpg
SDC13339.jpg [ 136.12 KiB | Viewed 753 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:43 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
You may have noticed a few continuity errors, some of the photos are not posted in the order the work took place, rather grouped together in what I think is a logical sequence. You may disagree
Next up is the flange for the rear closing panel
Attachment:
SDC13334.jpg
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Attachment:
SDC13335.jpg
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Attachment:
SDC13336.jpg
SDC13336.jpg [ 139.54 KiB | Viewed 753 times ]


This just leaves the outer sill, and the rear closing panel, then that'll be the underneath all welded up


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 10:11 pm 
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Put a SOC in it!
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Joined: Mon Feb 07, 2005 4:48 pm
Posts: 21718
Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
Coming on really well - good work, fella! :mrgreen:

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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Sep 20, 2018 7:00 am 
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Joined: Sun Jan 15, 2012 4:24 pm
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Location: Dunfermline
Car Model: 11 cars
Yep.. you just do it the way you feel happy with Greg...
It's getting there.. unlike ours.. no dig at you Al :lol:

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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Sep 20, 2018 11:20 am 
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Put a SOC in it!
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Joined: Mon Feb 07, 2005 4:48 pm
Posts: 21718
Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
Car 55 wrote:
It's getting there.. unlike ours.. no dig at you Al


I don't know what you're talking about... :wink: :lol:

I did discover the cause of the misfire recently - bugger all compression on #2 :shock: :? :wall:

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9-5 Aero 600Nm FB3
900 T16S track hack
96V4s


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Sep 29, 2018 5:20 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Thank you both for the encouragement.
Yesterday I did all the fettling needed to make the new outer sill fit neatly and applied seam sealer and zinc primer to the inside of the box section, but it was too windy to weld in the outside workshop. However, conditions were perfect this afternoon, so the outer sill is now fully welded in. Camera is on charge so photos to follow :corn:


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Nov 06, 2018 9:16 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Been ages since I last posted. Still making progress, although a new addition to the 'family' has slowed things down a bit.
It was a bit difficult to get a good photo of the new outer sill in place, so here's a bad one
Attachment:
SDC13350.jpg
SDC13350.jpg [ 124.93 KiB | Viewed 438 times ]

I've used the term 'a little skim of filler' previously. This is what I mean; just enough to tidy up the plug welds. My fabrication skills aren't good enough to do without it, sadly.
Attachment:
SDC13349.jpg
SDC13349.jpg [ 154.03 KiB | Viewed 438 times ]

...and the inner wing is ready to accept the refurbished rear suspension
Attachment:
SDC13354.jpg
SDC13354.jpg [ 187.92 KiB | Viewed 438 times ]


Last edited by greg124 on Tue Nov 06, 2018 9:40 pm, edited 1 time in total.

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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Nov 06, 2018 9:33 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
The rear beam and leading links have been completely stripped, new bushes put in and a couple of fresh coats of paint, and built up with all new fastenings
Attachment:
SDC13373.jpg
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Lots of cardboard on the concrete to stop that new paint getting scratched
Attachment:
SDC13376.jpg
SDC13376.jpg [ 183.63 KiB | Viewed 438 times ]

Balanced the centre of the beam on a trolley jack to manouvre it into position. Getting the washers in between the centre bush and brackets is really fiddly! If I was doing it again, I think I'd assemble the brackets onto the bush first, then bolt the brackets to the car.
Then realised I'd not installed the big grommets for the handbrake cables :wall:

Time to start building up the brakes. All new parts except the springs
Attachment:
SDC13377.jpg
SDC13377.jpg [ 211.33 KiB | Viewed 438 times ]

Just got the drums on before a heavy shower put an end to today's bodging. Still got to fit one split pin and the centre caps


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 07, 2018 7:26 am 
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Location: Dunfermline
Car Model: 11 cars
Excellent, looking great Greg...
Congrats on your new family member.. :D

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Focus B234
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7 Saabs
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Omega B234
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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 07, 2018 11:54 am 
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Put a SOC in it!
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Joined: Mon Feb 07, 2005 4:48 pm
Posts: 21718
Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
Aye, good work, Greg, as usual!

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S6 Avant 4.0 V8T 450bhp/550Nm
9-5 Aero 600Nm FB3
900 T16S track hack
96V4s


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Nov 13, 2018 9:30 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Thanks again guys.

Fitted the new springs and limit straps today
Attachment:
SDC13381.jpg
SDC13381.jpg [ 207.12 KiB | Viewed 347 times ]

Unpacked the Monroe shocks that I bought last year, only to find the fitting kits were for 2 pin shocks, not 1 pin and one eye. Dug out the invoice, and discovered the supplier went into administration in February. :wall: So I now need to source some lower bushes. Looked on the Malbrad website and can't see any , so any suggestions welcome...
Attachment:
SDC13384.jpg
SDC13384.jpg [ 207.29 KiB | Viewed 347 times ]

I'm really liking the look of these Toyo's on freshly refurb'd wheels with no hub caps 8)
Attachment:
SDC13383.jpg
SDC13383.jpg [ 190.74 KiB | Viewed 347 times ]

...and finally back on all four wheels for the first time since April. The car is VERY bouncy at the moment though


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 14, 2018 9:58 am 
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Put a SOC in it!
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Joined: Mon Feb 07, 2005 4:48 pm
Posts: 21718
Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
I'm sure I have some used conical dampers bushes if you need them.
The lower eye bushes are the same as for the later 99/C900 IIRC (ie not the early type with pin top & bottom). I think they're also the same as the fronts??

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9-5 Aero 600Nm FB3
900 T16S track hack
96V4s


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 14, 2018 10:40 am 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Thanks Al.
I just checked the eye on the new Monroe's against the old front shocks that I removed from the c900. They are the same bore and width; but unfortunately those bushes shot.
I'll send you a PM


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 14, 2018 3:35 pm 
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Joined: Sun Jan 15, 2012 4:24 pm
Posts: 2789
Location: Dunfermline
Car Model: 11 cars
Would SAABits not have them..?

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7 Saabs
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Omega B234
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