Not going to be able to have day after day of working on my car, but I can get some time in every now and then.

Many people dont know that my Z is high mileage. Currently over 163,000 miles, and the engine is still very strong, however the body is not. Years of jack damage has left some parts of the body exsposed to the salty roads and it has taked its toll.

My MOT is due in about a months time and I know that it wasnt going to pass in the state it's in now, so I decided to make a start on repairing the parts I know it will fail on. To start off, the drivers side sill had a hole you could get your hand in, and there is rust in the engine bay which needs sorting out, but today we are doing the sill.

 

 

To work on the sill we had to take the front wing off, which means taking the front bumper off.

Picture 1

Front Bumper removed.

 

 

Picture 2

Side view with drivers wing removed

 

 

After removing the wing it looked like it will needed a little work before putting back on.

Picture 3

Rust on drivers wing.

 

 

After having a poke round the sill area under the car a few weak spots where found, and some places went right through to the inside of the car.

Picture 4

Holes where the screw drivers are going though.

 

 

Picture 5

Another hole, near the accelerator.

 

 

The easiest way to repair something like that is to cut away the bad parts and weld on a plate. That meant cutting way some of the drivers side floor.

Picture 6

After cutting away some of the outter sill, a section of the floor is cut off too.

 

 

Picture 7

"Flintstones, meet the Flintstones."

View of the hole from inside the car.

Part II

 

A piece of welding sheet was cut to fit the hole and join on the lip of the sill. This meant creating the little lip on the sheet metal by bending it 90º a long the edge.

Picture 8

Piece of welding sheet cut to fit the hole.

 

 

 

The piece was held into place to see if it was a good fit.

Picture 9

View of inside with the patch in place.

 

 

Picture 10

Outside the car the metal is held in place by clamps.

 

Now the metal is held firmly my dad started to weld it to the good part of the cars chassis.

Picture 11

Welding action shot.

 

 

Picture 12

Welding action shot from under the car.

 

 

The welding seam is given some sealant and left to dry. Some was also applied to the welding on the outside too.

Picture 13

Welding sealant on the car.

 

 

 

Thats it for now. Probably do the rest over the next week or so. An hour here and there and it should be ready for when my MOT is due.

Looking good Stu.. Gotta say well done - not many people would have the balls to start ripping body panels off their car, and cut big holes in the floor! :)

 

Mind you, it probably helps that your dad is handy with a welder, hey!

 

BTW - if you're still after outer sills, would ones that had been cut off my old Z be any good? No rust, although the drivers side would need 'reforming' a bit where some dopey git crushed it with a jack (not me!), passenger side is perfect AFAIK though..

Money is really tight at the moment. I mean really tight. I wont have any spare money for a few months. I think we are just going to make some ourselves at the moment, as the rear needs doing too but we only have time to do the front. But it will most probably be an option later, but I dont know how long later. Thanks Aaron. ;)

 

Stuart

No probs m8 - they're still on the car at the moment, but I'll see if we can't cut them off when it gets broken, and I'll stick them in the shed, just in case you do need them ;)

Looks like it's coming along nicely, it's a big help for you that your dad is handy with a welder :cool:

Dave

Stu's dad, the naked welder - brave man ! LOL :D

 

 

Originally posted by DaveW

Looks like it's coming along nicely, it's a big help for you that your dad is handy with a welder :cool:

Dave

He was wearing a sleavless T-Shirt, but it looks like it though. ;)

Take no chances....

Aye we got all that stuff. But it was hot and my dad is hard. ;)

Srrae I dont think I have ever seen a Z in such bad condition:(However well done for putting the hours in and keeping it road worthy.

Rodney, did you see my first lot of pics about 2 months ago?

 

Stuart

Originally posted by smw1

Take no chances....

 

You just need some decent boots now :D

Originally posted by RodneyZX

Srrae I dont think I have ever seen a Z in such bad condition:

 

Is it mine in such bad condition? Or that I go looking for the bad parts? I bet there are a few Zs on here with rust that bad, but they just dont know it yet.

 

Stuart

Originally posted by SRRAE

Is it mine in such bad condition? Or that I go looking for the bad parts? I bet there are a few Zs on here with rust that bad, but they just dont know it yet.

 

Stuart

 

With Rod on this one Stu,Honest I never seen one needing that much welding:(

Show of hands of people who have jack damage?

 

Now how many people have actually cut away that area to see how far down the damage goes, and not just patched up the area so it "looks good"?

 

The usual attitude is to just slap an after market side skirt on and pretend its not happening. ;)

Originally posted by SRRAE

 

The usual attitude is to just slap an after market side skirt on and pretend its not happening. ;)

 

LOL what shite you talk!

 

My sills were perfect no rust at all:rolleyes: all the Kits Peter has fitted he only found 1 with bad sills.

I have jack damage on both sides of the car.

But I did test to see how far the damage went. The only bit on my car that needs welding is under the rear floors, there is a slight rust hole appearing.

 

I did mention to Peter about the rust from the jack damage and he said he will be sorting it.

 

I'm glad that he's got my car because I know is not going to be one of the people that will just slap a side skirt on it as you put it. :D

Originally posted by MAC 1

LOL what shite you talk!

 

My sills were perfect no rust at all:rolleyes: all the Kits Peter has fitted he only found 1 with bad sills.

 

 

Where the **** did I mention your car?

Originally posted by SRRAE

Where the **** did I mention your car?

 

Hey get your ****in head out your arse FFS!

 

I am not just on about mine I was also telling you about others Peter has done!

Fuck me and I thought MINE was bad LOL