Kevinlincs
Permanent resident
Posts: 1616
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« Reply #210 on: 24 September, 2020, 06:29:37 PM » |
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Worst bit around the vents now repaired, thankfully it hadn't spread down too far..
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #211 on: 24 September, 2020, 06:31:08 PM » |
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All welded in and smoothed out.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #212 on: 24 September, 2020, 06:32:25 PM » |
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Corner finished off too so that's all the windscreen surround finished off.
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Flavia 815 coupe
Delta integrale
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tzf60
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« Reply #213 on: 25 September, 2020, 01:00:32 PM » |
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Amazing work as ever, Kevin. You make it look so easy.......  Tim |
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1939 Series 1 Aprilia undergoing very slow restoration.....
Previous Lancias: 1979 Beta Sedan 2000, 1982 Delta 1500, 1988 Delta 1.3, 1992 Dedra 1.8ie
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nyssa7
Megaposter
Posts: 211
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« Reply #214 on: 26 September, 2020, 08:29:24 AM » |
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I was thinking of sneaking my car into Kevin’s garage and hoping he didn’t notice 😂
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2000 kappa coupe 20vt
1996 kappa saloon 20vt race car
the "Yntegrale"
1999 Lotus Elise S1
2016 AMG GTS
Y10 Advisor
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #215 on: 26 September, 2020, 01:19:51 PM » |
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Cheers guys, very much appreciated  With all the stuff in the unit I probably wouldn't notice another car  |
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Flavia 815 coupe
Delta integrale
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fay66
Permanent resident
Posts: 6233
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« Reply #216 on: 26 September, 2020, 10:27:17 PM » |
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It's not sneaking it in that's the problem, it's to get Kevin to do the work without realising it isn't one of his Brian 8227 |
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Own 1966 Fulvia 2C Berlina since 1997, back on road 11-1999.Known as "Fay"
2006 Renault Megane 1 5 Dci Sports Tourer
Dedra Technical Adviser
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #217 on: 26 September, 2020, 10:41:33 PM » |
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It's not sneaking it in that's the problem, it's to get Kevin to do the work without realising it isn't one of his Brian 8227 Yes, even I might notice that one |
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #218 on: 28 September, 2020, 09:09:08 PM » |
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Here's an example through the next few posts of how a little "surface rust" is actually and usually the surface of a much bigger problem...
The drivers door had a scab along the bottom of the outer skin and some rust on the underside of the bottom plate..
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #219 on: 28 September, 2020, 09:12:31 PM » |
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The holes in the bottom plate obviously mean that needs replacing but on looking inside the door the "surface rust" was on both surfaces! So nothing for it but to chop out the outer skin to reveal the horrors inside.. |
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #220 on: 28 September, 2020, 09:14:30 PM » |
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The further along I looked I couldn't see an end to the rust, nothing as bad but still rusted so couldn't be left, so nothing more to do that cut it all off..
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #221 on: 28 September, 2020, 09:17:22 PM » |
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Most of the bottom plate needed replacing apart from at both ends where strengthener plate sits, also there was rust up onto the edge up towards the door card aperture on one half so that needed replacing too.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #222 on: 28 September, 2020, 09:19:59 PM » |
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Then finally an outer skin could be fabricated for the bottom 2" or so. Door fitted back to the car along with the wing so I could make sure it went on square and to match the new sill. Use of the clico fasteners means it will go back in the same place for welding once back off the car.
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Flavia 815 coupe
Delta integrale
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Kevinlincs
Permanent resident
Posts: 1616
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« Reply #223 on: 28 September, 2020, 09:25:35 PM » |
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Bottom of the door skin repair panel got a folded flange as per the original skin which is bonded into place, a layer of seam sealer will tidy it up when the primer has dried.
All this effort for a bit of rust on the outside and a few holes underneath. Would have been quicker and simpler to have put some fibreglass filler in rather than spend a day and a half welding it but this way once all painted and treated it should last for years to come.
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Flavia 815 coupe
Delta integrale
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frankxhv773t
Permanent resident
Posts: 2245
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« Reply #224 on: 29 September, 2020, 10:53:33 AM » |
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I presume you will reinstate the three drain holes before painting.
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