Well the measuring, template making and cutting out has begun...

This morning I have hit the rusty hole area with my trusty wire brush attached to the MAKITA drill....

I finally found some solid metal to fix to and painted everything with some messy Rustins rust converter, including right inside the sill where there was some surface rust hiding inside.

Templates cut out ready for transferring to some sheet steel...

I shall be fabricating the repair panels later today at my work... I need to use the bench vice and I left my sheet steel and tin snips there... lol

I will update the thread when they are cut out and folded properly later or tomorrow!

Good luck with the repair Russ....:clover:

Good luck with the repair Russ....:clover:

 

It’s not luck Richard..... its stupidity..... lol

Well today I got the repair panels cut out and cleaned up ready to soak overnight in the Bilthamber Deox-C corrosion remover to get to any corrosion I didn't manage to strip with the wire wheel...

mainly in the jacking point layers....

Tomorrow I am going to round off the corners and then spray them with weld through primer to protect it until i'm ready to get under the car and start welding it in place...

Good luck

not for the faint hearted

Good luck

not for the faint hearted

Hi scoobydoo67, I’ve already fabricated one set of rear sill panels and welded it myself..... so hopefully it will go smoothly if I take my time and don’t rush it.... lol

I must be bloody bonkers..... lol

Well after a while making sure the patch section was fitting properly I fixed them in place with self drilling screws and added a few tack welds inside the car.

I had to beat the panels together in a few places to make sure there was no gap between them, so the panel hammers and dies came out and I began with a bit of fettling....

I was intending getting some more done, but had to stop due to weather getting a bit damp and running out of shielding gas.... lol

Tomorrow is my day to finish this off, grind off the welds, seam sealant and treat it with some rust preventative.....

Inside car..... top of patch area....

Good work mate keep it up it will come good in the end

Well she is all welded up and seam sealed.....

This was the inside after most of it was welded up on the inside joint.... I also welded the underneath as it was an overlapped joint.... both edges are now sealed and very strong....

This is the inside after cleaning up with wire wheel on the drill...

Next is the inside area with a coat of seam sealer applied....

And finally is the underneath with a coat of seam sealer to protect the welds and give it a bit of protection from stone chips while i was there.....

Not as pretty as I would have liked...... But I can clean up the welds when the weather gets better next year and i do the entire underside of the car and sills properly......

 

All i need to do now is cut off the end of one screw, primer and paint it all, sound deaden the inside, spray the inside of the sills again with Bilthamber, and replace the targa drain pipes with silicone ones......

 

Should be ready for MOT in a few days......... YAY!!!!!

Edited December 2, 20187 yr by veilside01702

Good work mate keep it up it will come good in the end

 

 

Thanks Ian....

Good work bud:thumbup:

Good luck with the MOT mate and well done on that repair :thumbup1:

Fair play to you Russ for your “Can do” attitude, I shudder to think what would happen to the Z if I was faced with all that :thumbup:

nice one Russ :thumbup1:

I wouldn’t worry about cutting back the welds Russ, it’s stronger as it is and it’s the bloody floor pan.

God I wish I could weld!

Well it is now seam sealed, painted inside with gloss black paint and underneath with a Matt black.

I also rubbed down the entire drivers side floor pan and bottom of sill, rust treated 2 small patches of minor surface rust.

Now fully painted floor pan. Next is to use some good quality underbody coating then the Bilthamber Dynax - UC clear underbody wax.

While I am at it I shall be giving the sills a new dose of Bilthamber Dynax-S50 cavity treatment....

I also fitted the new dynamatt sound deadening to the floor pan and tomorrow I shall be fitting the Dodo sound stopper LT under the carpet before I fit it back in place....

I wasn’t happy with the seam sealer underneath the car, so I stripped back to metal and reapplied some more.

Later today I shall be giving her another coat of paint and Schutz, followed by the Dynax-UC...

I finished the inside with some DODO sound stopper LT under the carpet for some added sound deadening where I removed the OE stuff to weld her up.

Should be finished in next day or so, if I am happy with the seam sealer when i look later...... if not I will be stripping again.... lol

OCD is kicking in I think..... lol

Well I looked at last nights work and have decided it is acceptable to me for the minute....

So this afternoon I gave her a coat of tetra schutz and am now waiting till tomorrow to check how it looks and see if it needs a second coat...

I have decided to do the other side while I am at it, as I noticed the sill looks like it has surface rust.... so its strip the other half of the floor pan day tomorrow with the wire brush. Then the same treatment as the other side, hopefully without the welding..... lol

Well NO MOT for a while.................

First of all after turning her around and starting on the other side for resealing the floorpan, I found this rotted through chassis rail......

 

 

Then I found this hiding behind the veilside side skirt on the opposite side to the one I repaired a few years ago.....

 

[ATTACH=CONFIG]115521[/ATTACH]

 

The filler is about 10-15mm thick in parts...... bodged up before i got her by the look of it.......

 

[ATTACH=CONFIG]115522[/ATTACH]

 

Anyone know if Luke at the Z centre is the best place to buy the repair panel???

Edited December 9, 20187 yr by veilside01702

I was a bit peed off so got cutting..... lol

 

Anyone know if Luke at the Z centre is the best place to buy the repair panel???

 

Luke or MJP Russ...…:clover:

I was a bit peed off so got cutting..... lol

[ATTACH=CONFIG]115525[/ATTACH]

 

Not so bad inside there Russ.... Mine was worse, going by the pictures Darren sent me - I must get a journal going....

 

…….But good luck with the repairs mate...:clover:

Ah man [emoji3525]

keep the faith Russ, you are doing some sterling work there buddy, and you know your car will be giving you faithful service back in spades once you are back on the road :thumbup1:

 

you are doing all the stuff that i know mine now needs, but i really don't have the ability to do it myself, so am busy building up the repair fund :lol:

Thanks everyone for the support......

I’ve ordered the Panel from Luke and I’m making the repair panel for the chassis rail by hand....

Just made a template tonight and will cut out the sheet and shape tomorrow......

Just need to find my joggler tool now....