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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Apr 18, 2018 7:29 pm 
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Full Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Cheers Mal.

Took these off to be sandblasted and powder coated a couple of weeks ago
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SDC13215.jpg
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Nasty old Barum tyres with badly cracked sidewalls were disposed of responsibly at the local recycling centre.
Then got these back on Monday with new boots fitted. I've gone for 165s.
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SDC13245.jpg
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I've only done 3 for now as I only have one pair of axle stands, so the other two wheels are currently on the front of the car. The guy who did the powder coating has promised so save some of this batch of silver for when I go back to get the other two done.


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Apr 18, 2018 7:46 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
It's been a lovely afternoon, so I've had an hour or so in the 'outside workshop' doing a bit more cut 'n' shut. Well, mostly cut.
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More old plated over rusty bits left to fester. There seems to be a common theme developing :( . It's so much easier to work on unpreboogeredaboutwith cars
Usual procedure
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...and a new flange let in
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I'm now pretty certain The Custardwagon won't be ready for Swedish Day, not his year anyway. No point rushing the job for an artificial deadline


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Apr 21, 2018 5:52 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
Repair section clamped in ready to weld
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SDC13247.jpg
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All ground off, and after a bit of hunting around I found a step cutter to make the hole for injecting waxy-oily type stuff at a later date
Attachment:
SDC13248.jpg
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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Apr 21, 2018 6:07 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
This has has offended me every time I open the drivers door
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SDC13249.jpg
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So it had to come out. First supporting where the inner sill meets the floor with blocks of wood to try and maintain rigidity. The repair section is thicker than the steel I've been using for the other areas, and has a coating that looks like zinc
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SDC13250.jpg
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The inner and upper surfaces of the sill have been treated to a coat of rust converter, then some of the zinc coating removed from the repair section with the flap wheel prior to welding in
Attachment:
SDC13251.jpg
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The lower section, which is generally referred to as the 'outer sill' will also be replaced, as it consists of repair upon repair. Just need to have a think about how to best form the two bends. Any suggestions gratefully received...


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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Apr 30, 2018 8:14 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Having removed the outer (ie. underneath) sill. More perforations were revealed :cry:
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So out with the cutting disk again
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Just call me Fred...
...Flintstone, that is
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That's better :) Can't fit the new outer sill just yet though. Bet you can guess what lurks beneath the rear seat


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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Apr 30, 2018 8:47 pm 
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Joined: Wed Jan 18, 2012 5:24 pm
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Location: Wigan, Lancashire
Car Model: 9000 Anni, 9-5s by the score
greg124 wrote:
Can't fit the new outer sill just yet though. Bet you can guess what lurks beneath the rear seat

A truppeny bit?

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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Apr 30, 2018 9:08 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
DeeDub8 wrote:
A truppeny bit?


About the right colour :wink:


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Jun 07, 2018 7:16 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
This was the mess under the back seat
Attachment:
SDC13256 (1).jpg
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I'll spare you the gory details, but it got the same treatment as the edge of the front footwell, and now looks like this. This batch of home blend hammerite came out a bit paler than the last. I'll mix up another batch for the second coat
Attachment:
SDC13277.jpg
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Ordered a pair of outer sills from Malbrad, as I only have the facility to bend sheet metal upto 30 inches long. The drivers one is now fitted. I plug welded it, to start with. Then decided to seam weld to the floor aswell. Then a skim of filler on the outer near-vertical section to hide the welds, and finished in Ford Daytona Yellow. Very 70's but maybe a little too bright - undecided yet :corn:
Attachment:
SDC13272.jpg
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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Jun 07, 2018 7:26 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
,,,and now to the mess in the boot that I've been trying not to think about
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SDC13222.jpg
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and under the wing, which had been left to fester
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Took ages to figure out the previous repairs, and quite tricky to remove the unwanted bits
Attachment:
SDC13234.jpg
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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Jun 07, 2018 7:32 pm 
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Posts: 625
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Attachment:
SDC13278.jpg
SDC13278.jpg [ 147.98 KiB | Viewed 1428 times ]

This is going to take several repair sections. Tomorrows task is to make a template and then fabricate a new section to go from the rear of this aperture to the first rib above the spring mount. That will give me some time to think about how best to tackle the rest :argh:


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Jul 04, 2018 8:04 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Last week I made a start on the corners of the boot floor, starting with the driver's side. Didn't have the camera handy when this was cut out...
Front corner sorted
Attachment:
SDC13285.jpg
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The blobby ridge around the repair section is seam sealer. I did grind the welds off tidy - Honest.
Having considered de-flanging the boot floor to eliminate the potential rust trap between the seems, I wasn't sure how much rigidity would be lost, so scrapped that idea and kept it 'original'.
Then the rear corner chopped out
Attachment:
SDC13283.jpg
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And welded in.
Attachment:
SDC13284.jpg
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I went for the tie down point (apparently it's not a towing eye) delete option, as the original had all but rotted away, I've done away with another rust trap. There will be a proper towing eye going in later, but not attached here...
At least this side was virgin rust. The passenger side is a whole lot worserer, as I discovered once I started chopping out - more rust sandwich :wall: But that's tomorrow's special job.


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Jul 07, 2018 12:53 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
The outside workshop is quite a pleasant place to work when it is in the shade, but in full sun it is too hot for fabrication.
This is a repair that was carried out by what the previous owner described as 'a classic car specialist' :park:
Attachment:
SDC13286.jpg
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A bit of an archaeological dig has revealed that he had just patched over a previous patch.
Attachment:
SDC13287.jpg
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I cut the side panel out first, leaving the floor as a reference for making the side repair panel. Fortunately I was able to cut below the three rearmost stiffening ribs, so only had to shape the bottom of one rib, and the wider depression to accommodate the road spring.
Then cut out the edge of the floor. Again most of the rust was outboard of the first rib in the floor, which makes things easier. There is just a piece about 2-3 inches long which had rusted through and been patched beneath the lateral piece of metalwork behind the fuel tank
Attachment:
SDC13290.jpg
SDC13290.jpg [ 209.73 KiB | Viewed 1302 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Jul 20, 2018 3:09 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Where's that hole gone?
Attachment:
SDC13293.jpg
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I deployed the remains of the rattle can of Daytona yellow that I wasn't liking on the sill. Seemed a shame to waste it.
...And this is the other side
Attachment:
SDC13294.jpg
SDC13294.jpg [ 131.77 KiB | Viewed 1203 times ]

So that's the boot floor finished


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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Jul 20, 2018 4:00 pm 
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Joined: Sun Apr 08, 2007 9:47 am
Posts: 3032
Location: Aberdeen,UK
Car Model: C900S LPT Vert, 99 GL, 96 V4
Coming along nicely. :wink:

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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Jul 23, 2018 11:59 am 
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Posts: 1993
Location: Lingfield, Surrey
Car Model: 93 Aero 2.8T cabrio
so much rust! Wish I had the time and space for a resto job like this.
keep up the great work.

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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Jul 23, 2018 1:35 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 gentlemen.
There is always about 10 times more rust than you first think :argh:


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Jul 24, 2018 12:53 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
When I pulled the handbrake cables through to remove the rear axle, some rust came away too around where the grommets go. At first I thought it was localised, but having a good poke around I discovered it extends beneath where the axle centre brackets are bolted to
Attachment:
SDC13297.jpg
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When making previous repair panels I've cut out cardboard templates first. However, yesterday I decided that a proper engineering drawing was required, i.e. on the back of an envelope, as getting the two small holes in exactly the right place is critical
Attachment:
SDC13300.jpg
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Then this morning it was out with the centre punch, a range of hole cutters and the bending kit to produce this
Attachment:
SDC13301.jpg
SDC13301.jpg [ 295.25 KiB | Viewed 1141 times ]

There are a couple of small patches of surface rust, but a little phosphoric acid with soon stop that in its tracks
Enjoying a bit of rain in Herefordshire at the moment, so the outside workshop might be closed for the afternoon


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Jul 25, 2018 7:52 am 
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Joined: Sun Apr 08, 2007 9:47 am
Posts: 3032
Location: Aberdeen,UK
Car Model: C900S LPT Vert, 99 GL, 96 V4
Impressive :shock:

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99 GL 1984
C900 16i Vert 1992
C900S LPT Vert 1993

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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Jul 26, 2018 6:47 am 
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Location: Dunfermline
Car Model: 11 cars
Great work, coming along at a steady pace now..

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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Jul 26, 2018 4:14 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Cheers guys.
Carosserie Gregory has been open for business again this afternoon. First cut out all the old grot
Attachment:
SDC13302.jpg
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Rear section of floor welded in, and new upright piece offered up. I inserted the bolts to make sure the holes lined up - which they do
Attachment:
SDC13305.jpg
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Put a couple of washers behind the bolt heads, and fully tightened them before starting to weld so as not to upset the suspension geometry
Attachment:
SDC13306.jpg
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Had to swap between left and right hand for some of the welding as it was a bit of a stretch, so some of the welds are not as tidy as I would like. Otherwise this section was a lot easier than I was expecting


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