I got underneath the car to do some sealing and rust preventative and managed to make 2 holes using the wire brush and a paintbrush covered in underseal.....

Can anyone advise me where to source section of panel I need ?

I want to cut out section and replace.......

I am trying to track down anyone I know who can weld.....

I am going to clean area up later with drill and wire brush to see how far the rot has crept......

Is this sill section or floorpan?

any idea of thickness of metal to use to make replacement section if I can't get replacement?

 

I even thought about aluminium mesh and JB weld for about half an hour......( I was a bit depressed when finding this so please forgive me!)......lol

 

I am getting more and more upset finding how many things need doing now.......

Edited August 27, 201312 yr by veilside01702

Dying to get on with the welding, but can't in case the little one wakes up and I need to pack up quickly.....lol

I might try to pull the drivers seat and do the other side if he stay's asleep.......

Aaaarggghhh.... too late, he's awake.....

Well that was today's work done.......lol

Right the wife is home and I am going to clean up the floorpan and get painting with hammerite....

Edited August 12, 201312 yr by veilside01702

Right today's work was.....

1) Fitted floor bung and seam sealed into floorpan

2) hoovered N/S floorpan and fitted Dynamat sound deadening from front bulkhead to rear seats...

3) Cleared out the boot and put all my parts into the garage ready to fit....

4) Pulled the N/A fuel pump and fitted a warlbro 255 fuel pump.... well I hope it was a 255 pump, seems smaller than the std one?

5) Cleaned every single speck of surface rust I could find in boot with wire brush....

6) Treated all rust in boot with Kurust....

7) Seam sealed entire boot......

8) Kurust painted into lower boot floor / rear qtr lower bits only accessible through either side in boot.... Below where the aerial is..... there was rust starting there, so treated it all.....lol

9) Painted boot with silver hammerite.

10) Removed drivers seat and got it ready to repaint the mounting frame / sliders.....

11) vacuumed carpet......... Looks almost new......:biggrin:

12) Injected passenger sill with dinitrol using the wand thing..... That stuff smells very strong.... I was a tad high.....lol

13) Sealed the inner inspection holes on sill with New sticky pad things......

14) Refitted ECU's and wooden cover, trim, etc in N/S floor area.....

 

And now I am going to garage to paint the drivers seat mounting frame.......

Frame painted and will be dry tomorrow.....

sounds like you've had a good productive day. keep up the good work.

You have been busy mate. Great work :thumbup1:

Cheers Dave and Gary...... I am busy with kids tomorrow so needed to get the car ready to be put back on the road....lol

I will be getting my 5 year old to help me clean the interior tomorrow though as he loves....'HIS' car......lol

Thursday I will be getting fabricating help, so going to be pulling drivers carpet and treating entire floorpan as I did on the N/S one....

Should have most of bodywork done in a week or so.... then it is strip engine again after reading Jeff's thread about belt fitting I am going to fit a genuine belt and check the adjuster is done right......lol

Well today I got some help and we fabricated the middle section of the sill and the lower wheel arch piece....

I still need to cut out the holes in the panel properly and put the flanges into the panel, but main part is done.....

Tonight is finishing the fabrication then to clean the parts with some degreaser and weld through paint......

I will post up pictures when I have finished fabricating the panels and they look presentable......lol

Oh and I cut out the entire bottom of the wheel arch..... was a big worry of mine till I did it and offered up the new panels and realised they would actually fit.....lol

[

Update:-

Well holes cut and flanges fabricated...... completely cleaned and degreased......Painted with weld 2 primer...... and welded up the slots in the wheel arch piece in my workshop....

finished welding in my workshop at 23.15..... can't grind the welds on that one as my neighbours would lynch me.....lol

ATTACH=CONFIG]72706[/ATTACH]

I will clean up and paint tomorrow..... I will post pics of this bit then.....

Edited August 15, 201312 yr by veilside01702
updating info

Some nice fabrication going on there mate, especially photo 2. As for photo 1, have you compared it to the opposite side?

I really do not want to rain on your parade but the curve does appear a bit abrupt. I am just a bit worried for you because this will finally determine the outer shape of your rear sill. I know you are planning to cover this with your skirts, but I am a little concerned that they will not sit well.

Please do not take this the wrong way, It's just that I know how important this car is to you and how the car will look when finished.

No offence meant mate.

Some nice fabrication going on there mate, especially photo 2. As for photo 1, have you compared it to the opposite side?

I really do not want to rain on your parade but the curve does appear a bit abrupt. I am just a bit worried for you because this will finally determine the outer shape of your rear sill. I know you are planning to cover this with your skirts, but I am a little concerned that they will not sit well.

Please do not take this the wrong way, It's just that I know how important this car is to you and how the car will look when finished.

No offence meant mate.

Hi Dave, It doesn't look good in that picture now I had a look.....lol

The wheel arch piece was tested against the original piece, as I left that in place till the last minute and made a template from inside the wheel arch of the radius and where that is in relation to the bottom sill joint and the end of all the sill pieces.....

If that makes sense....lol

I used a piece of card, drew the curve and marked the ends of all the pieces of the sill on it.... if that makes more sense....lol

I then carefully removed as little as possible from the wheel arch and checked my marks were all the same....

I carved a wooden copy of the original piece with the same radius / curve, length etc and carefully beat the flat steel sheet over this former.... I did have to make 2 cuts that in that picture look bad....

Since the picture I reworked the bend and welded up the cuts.... I will go and take a picture in a moment and try for a better angle so you can see what I did, hard to photograph this piece well.....lol

I do appreciate the help and advice and am taking everything onboard..... Thanks for the complements on pic 2.....lol

That was fun getting the correct bends, length, etc..... the easiest part was making the holes and flanges.....lol

Sort of like this.... roughly placed....

Painted with Upol weld2

I took loads of pictures and they all came out blurred with the flash and silver spray....

Edited August 16, 201312 yr by veilside01702

fantastic work mate. Really impressed :cool3:

fantastic work mate. Really impressed :cool3:

Thanks for that.... I keep looking at everything and thinking I could do better..... and then thinking it won't be seen again till it too rusts away......lol

But then I think, what will the next person repairing her think of my work?......lol

Little bits that show tooling marks or aren't quite straight or curved as I would like..... I nearly re-did pic 2 of the inner section with holes as they are a few mm off of perfect, then decided I will adapt them when I go to weld it up or adapt the original piece I am welding to.....

Can't wait to get grinding and welding again now......lol

 

I must return the compliment Car.Mad as your spoilers are superb.......

No looks good mate the zeds floor is so up and down and goes everywhere it's impossible to get it perfect. Plus it's better than a big hole and I'm sure a new buyer would prefer to see that than a massive hole lol

Right Driver floor now had coat of Kurust on any surface rust after I wire brushed it...... painted entire floor with silver hammerite....

I did find a big round lump sticking up where someone has jacked the car on the chassis rail at the back and it slipped off..... perfect indentation of trolly jack cup.....lol

It was where the rear seat curves up..... Used a bolster chisel to work it round and rubber mallet to ease the floor back to shape..... Really happy as you can't even see it was there now and underside looks perfect.....

Going to dynamat the floor pan later and refit carpet after the welding and grinding are finished, just in case of a spark or heat......

I have been trying to work out what to do about the drain for the targa.... I thought about changing exit point to wheel arch or using silicone hose.....

But have opted for using a water pipe from the plenum delete and cutting it down, running it out of original hole and extending it from sill by a few cm......???

I will try and get a pic of my idea later........

 

Out with kids today, so won't get much done till this evening and then it will be dynamat floor and boot, make sub box templates and work out boot install layout.....lol

Nice mornings work Russ I have manged to drink a cup of tea this morning and empty the dish washer so you put me to shame mate:biggrin: Enjoy the rest of the day with the kids Russ:thumbup1:

Well today I have kids all day on my own so only got to cut off water pipes under plenum and throttle bodies, remove windscreen trims and wash them ready for wrapping with a bit of carbon fibre 3D film... Better than what they currently look like...

Just got to strip the targa's now and do them as well as recover the inside as they are all wrinkly....

 

Tomorrow is grinding and welding day...... Yay..... I am going for closing the first repair panel and fitting the home made Targa drain tube..... Made from one of the many pipes deleted from my plenum.... Turns out it is the same size as the rotted original metal pipe.... I have cut it and painted in zinc primer.... it is going to protrude from the sill by a couple of cm..... should help with rotting problem.... I have also considered using some silicone hose to replace the original clear plastic pipe....

If I get time I shall be tacking in the bottom wheel arch repair panel and the middle panel, just expecting this to take a while as I want it right......

 

Also where is the cheapest place to get disposable Argon / CO2 Gas bottles? I am paying £14.39 for 110 Ltr bottle from Machinemart....

I looked at renting a big bottle, but would need a bottle and valve.....

I am paying £14.39 for 110 Ltr bottle from Machinemart....

 

Wow!-110 ltr -you won't get cheaper than that LOL!

I've got a hobbyweld bottle, works out a lot cheaper. Search for your nearest supplier on there site mate.

It's £50 deposit for bottle and about £30-35 for a refill last time I got 1 earlier this year. You will need to get a new regulator though but does work out a lot cheaper.

With the targa drains it might be worth doing what myself and a few others have done and bring the hose itself out the bottom if the sill. I chose that way as there is no joint inside that could ever leak and the pipe can't rust or clog etc.

up to you but worth considering IMO.

Wow!-110 ltr -you won't get cheaper than that LOL!

Yep..............

Well I have been grinding and welding since mid day and have finished for the day as I ran out of mig wire.....lol

Here are a few pics of todays work....

Before...

Wheel arch and first panel welded in....

Middle panel welded in place, looks rough but ground down looked a lot better.....

Ground down and painted with weld 2 zinc primer....

And kids are home, so have stopped till I get wire and time to carry on.....

Well done Russ, looking a cracking job mate, don't worry about grinding the welds on the inside no one will see them and it adds to the strength.

 

Paul

Well done Russ, looking a cracking job mate, don't worry about grinding the welds on the inside no one will see them and it adds to the strength.

 

Paul

Cheers Paul.... I just took the top off the welds and painted them straight away to keep them rust free....lol

I am now trying to work out if I should use a joggler to attach new outer panel edge to original rear quarter panel.... I was thinking of using it on the original panel and creating a flange to overlap the joint for the outer skin?

Or should I just seam weld it and butt it up?

I am getting nervous now as this will be the panel you see and it needs to look right......lol

I was amazed how comfortable some of the welding felt today.... It actually flowed nicely and I had some nice seams with good penetration for once.....lol

I have found that I need to take off the rear wheel to get to the arch to weld..... Nightmare.... As car is already over the max height of my trolley jack and on big wooden blocks under wheels.... so need to loosen wheel bolts, get jack + wooden beam under jacking point and remove wheel....

Guess what I'm up to tomorrow.....lol

looking good Russ

its a bit of a compromise on the seam type. i butt welded mine as i was concerned that the overlap on the inside would be a rust trap. the down side to this is its so easy to blow holes. the best solution to this is do a series of overlapping tack welds, this also helps keep the heat down which will warp the pannel. ive just finished all mine if you want some pointers plus lots of pics about half way through my build thread. still took a bit of filler to get it back nice though, unless you are going to stone chip

I would go for over lapping the panel much less pain that way lol. rust won't be a problem as you have rerouted the drain pipe and i'm sure you will be spraying some anti rust into the sill.

 

Paul

its a bit of a compromise on the seam type. i butt welded mine as i was concerned that the overlap on the inside would be a rust trap. the down side to this is its so easy to blow holes. the best solution to this is do a series of overlapping tack welds, this also helps keep the heat down which will warp the pannel. ive just finished all mine if you want some pointers plus lots of pics about half way through my build thread. still took a bit of filler to get it back nice though, unless you are going to stone chip

Hi dougal200, I did the first repair panel by butting it up to the old section and tacking it on with a small gap between pieces and then filled the gap with a seam weld between the tacks. I moved from one section to another to keep the heat down as well as compressed air to cool the welds. I did the middle section with the 3 holes as a butt weld on the ends and an overlap at the top, but overlapped from the outside so I could seam weld the gap to stop water being trapped in there. I can get to the inside through the rear quarter panel so I can get a bit of seam sealer and paint on it. The overlap is like this....

Then everything I can get to has been painted with zinc paint....

Going to do hole in front sill section today and see if I can jack up the car to remove rear wheel and finish up wheel arch today.....