Kevinlincs
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« Reply #60 on: 09 May, 2021, 03:07:11 PM » |
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You will no doubt have noticed how rusted the repairs had become on the inside in just a short time, the old rust just transfers to the new metal, why it is vital to protect the inner repaired sections.
With the outer sill cut away it became clear wy the sill lip had folded so easily, the central reinforcer had rotted away and left unrepaired, this will all get redone.
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Flavia 815 coupe
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Kevinlincs
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« Reply #61 on: 09 May, 2021, 03:14:04 PM » |
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I'm hopeful that the chassis itself will clean up enough to be useable but if not I will cut it out and make a new section.
There is a small hole at it's forward end that had been undersealed over which needs repairing.
I've decided that the rear axle will need dropping out so I can get at some rust that's forming around the mounting points, which also means that the fuel tank will have to come out. Not all bad as I wanted to check around the inside of the fuel filler neck in the inner arch anyway where they can rot.
Also with the axle, or more accurately the hubs out of the way then repairing the seams between the boot floor and inner arches becomes much easier.
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Dikappa
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« Reply #62 on: 09 May, 2021, 04:22:30 PM » |
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Never a bad thing to have the fuel tank out of the way when welding so close to it...
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Kevinlincs
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« Reply #63 on: 09 May, 2021, 04:37:27 PM » |
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Never a bad thing to have the fuel tank out of the way when welding so close to it...
Very true, especially a plastic one! |
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Kevinlincs
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Posts: 1615
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« Reply #64 on: 12 May, 2021, 09:07:55 PM » |
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As work seems back to normal I'll be able to get Wednesday afternoons at my unit to keep things ticking along on the Dedra now.
The drivers side rear jacking point needed making up. I like to fit a strong point with a large washer that will suit a trolley jack but also I use a home made adapter that fits in an upturned axle stand thus pinning the car down safely preventing it from being able to slide off, I'll demonstrate it later when I get the axle off.
Once the box section was welded to the chassis side the rest of the sill could be repaired including the missing central reinforcer and then an outer sill repair piece let in.
The hole at the front where the passenger footwell begins got a new piece let in underneath the end of the chassis rail then that tapped back down and welded solid.
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Kevinlincs
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Posts: 1615
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« Reply #65 on: 12 May, 2021, 09:15:19 PM » |
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I will box the sill end in later on as I need to remove more of the inner arch where it had previously been repaired but not all rot removed.
As I mentioned earlier, I will now definetly be taking the tank and axle out as not only is there some rust above the axle mounts but the fuel filler neck and vapour tank area also has corrosion which needs welding up.
Probably get it all out on Saturday then next Wednesday I can start chopping more rot out. Still, it's not as bad as I thought it was going to be.... Risking a certain amount of fate tempting...
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Kevinlincs
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« Reply #66 on: 15 May, 2021, 08:49:12 PM » |
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Managed to get up to the workshop this afternoon for a few hours so got the fuel tank and back axle out.
Hardest part was trying to get the car manoeuvred off the stands and onto the new jacking points, fear of the whole car toppling sideways meant a nervy time but its now secure again.
Some rot found behind where the fuel tank filler sits, nothing drastic. The seam looks like it may need a repair after all, I'll have a look at it on Wednesday afternoon to see if I chop it all out after all.
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Kevinlincs
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Posts: 1615
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« Reply #67 on: 15 May, 2021, 08:54:04 PM » |
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The rear axle doesn't look too bad, a bit flaky in places so I'll take it all apart and get it blasted.
If I can find new bushes I'll get it powder coated, if not then they will stay in and I'll wet paint it.
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Kevinlincs
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« Reply #68 on: 17 May, 2021, 08:42:54 PM » |
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Took the axle to work as thought I may have to press the old mounting bushes out, with the underside supported though a good whack with the hammer and they popped out easily, are only held in by a 10 to 15mm section of the axle so didn't put up much resistance.
I've also stripped the trailing arms down and have just put in a £200 order for new axle bushes, 4x flexi hoses, discs & pads, backing plates, rear hubs/bearings, load compensator valve and hand-brake cables.
I am as yet undecided on the axle beam, just get it blasted and red oxide painted by the blasters then paint it when I've fitted the bushes, or get it blasted and powder coated but run the risk of chipping the powder coat when fitting the new bushes. I favour the former, and painting once the bushes are fitted will seal them.
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Kevinlincs
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« Reply #69 on: 22 May, 2021, 10:45:52 PM » |
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With the axle out of the way I got a better look at the seam between the floor and inner wheel well.
I know I said I expected it to be all rotten when I got the car and was amazed at how good it was... But now I have seen it I will just go ahead and chop it all out as although it hasn't gone through all along it is rusty enough to warrant removing.
I started off on the passenger side as that is the worst, the area around the seat belt mount was rotten in the seam. I thought about leaving the piece where the ABS and suspension wires go through still in place but on the end it's best to just get rid of anything in doubt.
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Kevinlincs
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« Reply #70 on: 22 May, 2021, 10:49:17 PM » |
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The reinforcer that supports the seat belt mount needed remaking as the old one was rusted and I actually previously cut in in half! Some 2mm steel did the job. This section stretches down and links in with the sill end so is a strong repair piece.
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Kevinlincs
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« Reply #71 on: 22 May, 2021, 10:51:24 PM » |
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The aforementioned seam was next, I could have just cut the wheel well section out but decided a belt and braces approach was best, no point in doing things half hearted.
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Kevinlincs
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« Reply #72 on: 22 May, 2021, 10:54:13 PM » |
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I needed a floor section and a vertical wheel well section which I planned to spot weld together leaving a hanging flange to provide a drip edges water would be discouraged from travelling towards the floor. Space would be a bit tight so I made it in one piece off the car.
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Kevinlincs
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« Reply #73 on: 22 May, 2021, 10:56:51 PM » |
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3 channels hammered in then fit for lining up to the car, all nice and strong now with clean metal.
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Kevinlincs
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« Reply #74 on: 22 May, 2021, 11:02:03 PM » |
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Bit of a clean up and some etch primer sprayed in then that's it for the afternoon. I'll carry on around the side next visit, whenever that may be.
I'm going to try and get it all done this summer but also I've decided not to put pressure on myself to get it done so if it isn't done then so be it, life goes too quickly to spend every spare moment on these jobs.
I'll keep the updates coming as and when, if anyone is still interested.
I'm determined to make as good a job of it as I can as I want this car to be a keeper.
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