Dedra turbo H630 XGN

[Kevinlincs]

A week or two since I've posted, I've been distracted a little by an Alfa GTV that I seemed to have bought, and a Toyota MR2 as it happens, but if truth be told I've been putting off doing the inner arch repairs as it really is a pain to do, welding upside down and trying to create a 3D repair out of fresh air.
But with the day off work today I had to get to it.
The remaining rotten edges were cut back an dthe an attempt to make a panel to cover at least half of the the inner arch was made, but it became apparent that I'd be ages, days even trying to get a single panel formed that would fit everywhere so the simplest solution was to make several smaller panels.
The section under the little bucket where the door lock mount is got a simple enough panel made up and allowed the lock bucket piece to be spot welded to it for added strength.

[Kevinlincs]

The inner, car side of the rearmost section was next, finally time to join up the repaired floor pieces.
Not the prettiest repairs but all rust has now gone and it's solid again.

[Kevinlincs]

Time to make the sections that will link to the new outer lower 1/4 panel, once I make a new one!
A new full length curved piece needs making for the curved arch but the straight piece is about right height wise, it will gain a horizontal return section once things start going back together on the outer piece.
Once that's all in place then a new bumper mount bracket can be made so still a bit to do!

[Kevinlincs]

I've finally got back to working on the car now the temperature has eased a little, getting wrapped up for welding in near 30 degrees outside but far hotter in the workshop was not for me.
The drivers side looked OK but of course at this stage the sensible thing to do is just cut out any doubt, so the seam cut removed as the passenger side did.
This side however isn't a straight lip as it curves to clear the fuel tank filler neck. Some use of the shrinker/stretcher to make a curved repair piece before spot welding a new side piece on, similar to the other side.

[Kevinlincs]

Copious amounts of etch primer ensures that it runs into the seam, later on the seams will be seam sealed but it is vital that no hidden areas are left with bare steel especially where welded as that encourages corrosion to set in.
Weather permitting I will get up there on Wednesday and get some more done.

[DavidLaver]

Delighted to see some metal working action again.

Loved our Dedra Turbo, that we swapped for a car I didn't love when trips to Barry Waterhouse Engineering for the work on it became too much, a couple of months after my eldest was born, which was when the tax expired on the Austin 7 special, etc...

[Kevinlincs]

Yes, I remember our Dedra turbo well David to, a great family car that covered most bases, fast and comfortable, very good sized boot especially with the folding rear seats, rare and non descript enough to be able to be left anywhere and it be still there on your return!

I managed to get some more welding done this afternoon. The drivers side rear floor was a bit rusty on the underside, not enough to be holed but whilst I'm at it the section was removed and a new one made and let in, complete with the two holes needed for the ABS sensor wires and the electronic shock absorbers.

[Kevinlincs]

Inside rear drivers floor.

[Kevinlincs]

The sill end boxed in, with 25mm hole for access to the inside so it can be blasted with cavity wax, I use a hole cutting drill to suit the rubber grommets, always handy.

The nut is for the seat belt anchorage point, needs to be pretty solid of course!

[Kevinlincs]

Underside will get seam sealed over all the welds once the etch primer has gone off, once the seam sealer has been on a few days and the solvents dried out it will all be given a coat of stoneguard protection then some 2pack red paint along with the inner arches.

Still got the chassis rails to clean up of course, and the passenger outer arch to make up and fit, and the rust behind the fuel filler mount, and the bumper mounts... So the painting the underside stage is still some way off!

[Kevinlincs]

The welding is almost done now, beavering away the last few days whilst on holiday, of sorts.
Today was supposed to be just a day to tidy up a few bits and seam seal all the welds before it all gets stoneguard applied at the weekend.
As ever though there's always a bit you miss, this time a crunchy looking part behind the bumper mount that attaches to the back panel.
The bracket got the spot welds drilled out so it could be removed to be reused then a new outer panel made up with the section for the boot floor.
Another smaller section further along needed doing too.... So fingers crossed that's it for the rear end..

[Kevinlincs]

I've also taken what may seem an unusual decision and enlisted a friend who does paintwork full time to prep and paint the bodyshell for me. Not because I can't, but because I can't see me having the time to get it all done this year with work and all.
This way it will be fully painted by mid September so I can concentrate on getting it all back together without it sitting there until next spring awaiting my attention, and I'll get my spare time back.
Part of the decision to thin down the fleet, although the Flavia coupe may get to stay as a retirement project!

[Kevinlincs]

Last Saturday all the welding repairs got covered with the stonechip protection, this provides a nice thick rubberised layer over the etch primer and seam sealer so it should keep the moisture out.

[Kevinlincs]

I was going to leave the insides smooth but as I say, this stuff gives good coverage and protection

[Kevinlincs]

This afternoon I put the red on so it will be dry by Saturday so the axle can go back on. Was just going to do it in black but as I had the proper colour I did it red so I could also do the insides at the same time.