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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Jul 28, 2018 2:28 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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
SDC13309.jpg [ 324.26 KiB | Viewed 497 times ]

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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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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 399 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:11 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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
SDC13326.jpg [ 271.38 KiB | Viewed 217 times ]

Front section done
Attachment:
SDC13340.jpg
SDC13340.jpg [ 148.51 KiB | Viewed 217 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:18 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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 217 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:28 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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
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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 214 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:36 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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
SDC13338.jpg [ 149.7 KiB | Viewed 214 times ]

...and welded in
Attachment:
SDC13339.jpg
SDC13339.jpg [ 136.12 KiB | Viewed 214 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 19, 2018 7:43 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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 214 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: 21661
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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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: Thu Sep 20, 2018 7:00 am 
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Joined: Sun Jan 15, 2012 4:24 pm
Posts: 2782
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!
User avatar

Joined: Mon Feb 07, 2005 4:48 pm
Posts: 21661
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:

_________________
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: Sat Sep 29, 2018 5:20 pm 
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Light Pressure Turbo
User avatar

Joined: Tue Feb 28, 2017 2:59 pm
Posts: 563
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
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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