Hi Guys,

Well its been a while but my beloved zed has been sleeping quietly in the garage underneath an indoor cover,

but unbeknown to me has been rusting without me knowing, really annoyed. ( how its rusted in an indoor garage is puzzling me )

 

first sign is a fuel tank leak, so began the process of removing the rear tank,

 

looking under the rear arch behind the bumper, it has rotted through, this has been repaired before but again has rotted through,

does anyone have any pics or experience with repairing this section?

 

looking under the zed it looks like I will be dropping the subframe and using a product called POR 15

http://www.frost.co.uk/semi-gloss-black-por15-rust-prevention-paint-946ml.html

 

I have sprayed loads of waxoil and stone chip under the arches that did nothing to stop the rust, what is the best way to clean it all off to bare metal so I can do a proper job?

 

any help would be greatly appreciated regarding dropping the rear subframe, and redoing the brake pipes, do these need to be done as

a complete section front to back, or do you join them somewhere, ive tried the search function but I need a little more help with the brake pipes

and hicas pipes that seem to have rotted

 

any help greatly appreciated

Agreed.

I can both sympathise and empathise having done similar myself.

Respect. :thumbup1:

 

I would recommend a good mask when welding galvanised steel, I believe the gas is somewhat poisonous.

 

Just a thought, are you contemplating any bracing?

The rigidity of the shell is predominantly based around the sills themselves.

Hi matey

I sure have considered bracing in the sills as you rightly say they are the backbone of the zed, im going to deffo rebuild the inner sills and strengtheners and see what else i can do

 

Galvanised is leathel stuff so i will be wearing a mask when welding, bonding the sills on are my other option im thinking about

Good work mate. The bilt Humber products are great, I used them on mine. As you may be aware, the cavity wax is quite flammable.

As red wine pointed out, please be very careful with welding the zink, it is highly toxic when welded.

 

I found the dinitrol rc900 very flamable also had flames licking up from my sills so had to fire a hosepipe down there was relieved and gutted at the same time

A bit more update on the parts that I have refurbished before it all goes on,

everything nearly has been shot blasted and painted with a product called POR 15 looks really good stuff but you have to take your time and

do the prep work properly

 

the brake pipes are new using kunifer and I have used heat shrink on the brake pipes for that factory look

 

Edited May 6, 20178 yr by FASTREDZ

Well done mate, your doing a proper job there.

Well done mate, your doing a proper job there.

 

Ditto..... Inspiring.

Just taken the bumper off mine at the rear and now makes me worried what I might have in store! But at the same time, inspired by the excellent work you've done!

Thanks for the inspiration guys :)

 

im happy on how the work is coming on albeit very slow .... all this work would have been avoided if I had waxoiled all the cavities when I first had the zed

ah well hindsight is a wonderful thing,

I have found that wherever was welded before that was where the rust has hit the worst.

Im still stuck for an inner wing for the drivers side rear if anybody knows of one going,

 

im doing the sills at the moment and im doing them in galvanised, plenty of pics to come as I work my way through :)

Onto the sills now, I bought some 1.2 mm galvanised sheet steel, Now lets be clear about this... Galvanised is very nasty stuff

to be welding the fumes it gives off is highly toxic so all the welding has been done using an appropriate respirator mask under my welding mask

 

so now health and safety is out of the way lets see what we have done so far,

 

Cut and formed the steel to match the old parts that have been removed

 

the sill has been stripped from the inside to the outer sill that has been patched up and treated with bilt hamber zinc primer and dynax seam sealer on all welds

 

Next the middle sill

next the inner sill has been test fitted before welding, I will update as I go along

Do you recon that's been easier from the inside? Looks like it makes sense and especially if your working outside a breeze can ruin your work particularly using CO2.

Do you recon that's been easier from the inside? Looks like it makes sense and especially if your working outside a breeze can ruin your work particularly using CO2.

 

for me it was the only way as the outer sills have a fiberglass side skirt that has been blended into it

as for doing the job from the inside its great the only problem is when you get to the bulkhead its quite tight in there and I had to cut a section

out of the floor to access the sills, but the floor was rotten anyway so had to be cut out

Brilliant work there mate. :thumbup1:

Onto the calipers now,

Fully stripped down and shot blasted, I split the front calipers and in my moment of madness I have forgotten which calipers half match as they got mixed up

im sure they wont make a difference, but its good practise to keep them matched

 

so after shot blasting I cleaned the cylinders of all marks and polished them,

painted them using http://www.brakecaliperspecialists.uk/brake-caliper-painting-kit/ in post box red, They even added white paint for me to do the lettering very kind of them

 

then I used http://www.biggred.co.uk/brakecaliperrepairkit_brk204015 for the front And http://www.biggred.co.uk/brakecaliperrepairkit_brk203840 for the rear

 

Now when I fitted the rear seals there was a big lip on the rear caliper casting to stop the rubber boots sliding off

when on the other hand I fitted the front there was no lip at all on the casting and this allowed the rubber boot to slide of easily,

I used the old caliper boot rings, as the new clips from bigg red tended to slide off the boot quite easy

anybody else noticed this?

 

Nice work.

Looking good bud.

Well kind of a lot has happened since rebuilding the zed

I became a dad to a beautiful little girl called Erin

So my work on the zed is limited to say the least

Saying that, the subframe is up, fuel tank is in and the diff is in.

 

Now onto the rear brake pipes i need a little help

 

I have forgotten what plastic and metal clips go where,

 

Im looking from where the brake pipes come out of the rear chassis all the way to each of the rear calipers.

 

My brake pipes are in place, but just need to know what bracket/clips go where if anyone can help.

Congratulations on your daughter Fastredz and hopefully someone will be along soon to help you with the brake pipes.

Congratulations on becoming a dad. Just keep worrying, working and playing with your baby, time really does fly bye. As for your daughter I'm sure she'll be fine. :wink:

 

This post is great by the way, top work! :cool3:

Well kind of a lot has happened since rebuilding the zed

I became a dad to a beautiful little girl called Erin ����

So my work on the zed is limited to say the least

Saying that, the subframe is up, fuel tank is in and the diff is in.

 

Now onto the rear brake pipes i need a little help

 

I have forgotten what plastic and metal clips go where,

 

Im looking from where the brake pipes come out of the rear chassis all the way to each of the rear calipers.

 

My brake pipes are in place, but just need to know what bracket/clips go where if anyone can help.

 

Congratulations mate. Mines 11 months old now and I’ve done very little on the Z recently. Make the most of it whilst she’s still and napping a lot, mins crawls now and is a one woman army of destruction and distraction:lol:

Congratulations on the birth of Erin mate...... :thumbup:

Thank you for all the best wishes on our new Daughter :biggrin:

I have seen that my time is much more precious now where on earth did I waste my time before she was born I don't know :pinch:

 

So the zed is still in pieces, but I have more or less finished one side that I am very happy about, Still to do the inner arch and sills on the other side

its coming slowly, but more important I know its now getting to be 100% rust free or near as damit.

 

just need to know where the rear brake pipe clips go??? if anyone can help out, anyone have there zed up on ramps or in the air?

Congratulations and remember when it comes to new family members and owning a Z32:

 

Congratulations and remember when it comes to new family members and owning a Z32:

 

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What a brilliant picture :cowboy: thanks for the wishes matey :)