And So It Begins....

[SanRemo78]

Another chance to go see the progress was taken yesterday! There are pictures of the state of the screen surround earlier in the thread. Plus the VX donor cut that wasn’t much better. Anyhoo, Geoff has almost finished this area off. The entire outer skin from side to side plus an inch back from the top of the screen was removed. Then the inner skin removed and replaced. The replacement screen surround was made up, full screen perimeter and joined to the existing forward edge of the scuttle. Then it was welded in. Screen offered up which highlighted an issue in the corners that was resolved with a bit of further work with the stainless surround as a guide. Just a bit of lead loading to do for perfection. And then onto the next grotspot.

[peteracs]

Hi Guy

Hope you do not mind, I rotated the photos as I could not get my head around them at the odd orientation.

Looking good, I guess he has some free time!

Peter

[SanRemo78]

Thanks Peter!

[SanRemo78]

Going to visit the shell tomorrow but not expecting huge progress. I had a delivery today after an anxious wait of 4-5 weeks. Luckily customs didn’t nab it and it survived shipping without any major damage. After the windscreen surround this was the worst panel on the car.

[peteracs]

Hi Guy

Glad you found one and no customs charges, full result.

Peter

[HFStuart]

Like me bringing back an HPE rear 3/4 from Belgium on the ferry and trying to look innocent as I drive through customs. One of the benefits of an anonymous small saloon, you don't look too much like a smuggler.

[SanRemo78]

It's a few years (and pre Brexit) when we moved Andrea from Germany to the UK via Rotterdam in a LWB Mercedes Sprinter and went through the nothing to declare channel. Naturally we got pulled over and got asked about cigarettes & alcohol. Since neither of us smoke and Andrea doesn't drink the answer was none. They didn't believe us but didn't look any further than the side and rear doors from where they could see all her worldly goods.
Except the Ford Escort she'd driven across in a few weeks earlier that had all the contraband. Well, a couple of crates of beer and a few bottles of wine, within our limits at the time.
These days it's probably not worth the hassle of getting caught... M'lud.

Guy

[SanRemo78]

Minor progress, the fabricator is busy with other stuff running in parallel!

But the small grotspot on the front crossmember and the top surface of the left sill/B post and wing had been fixed. Properly.

[SanRemo78]

And on a worse note, we scraped off the sealant on the outside top edge of the rear turrets to find the steel on the inner wing above was AWOL. More fabricating to be done.

The next task will be to chop out the rear panel and stitch in the new one in. Then it can come off the lift and go onto a spit for better access.

Progress is slow but there is progress!

Guy

[WestonE]

Well done Guy for making it happen!

[chrisc]

And on a worse note, we scraped off the sealant on the outside top edge of the rear turrets to find the steel on the inner wing above was AWOL. More fabricating to be done.

The next task will be to chop out the rear panel and stitch in the new one in. Then it can come off the lift and go onto a spit for better access.

Progress is slow but there is progress!

Guy

You'll still probably be done before mine

[SanRemo78]

Back panel cut out… the panel underneath that needs work too. The outer skin is excellent, it’s the inner skin that’s been eaten oddly. The left side had a few patches and whilst the right side will need work too, across the rear edge, it gives Geoff a pattern to duplicate the repair panel to.

[SanRemo78]

More progress since Christmas! After the rear panel was removed Geoff could get at the top of the lower panel which looked like this after a couple of patches were removed. He's cut away all the rot, fabricated a new upper panel for this box section, hoovered out all the flakes of rust and welded the repair panel in.

[SanRemo78]

The new rear panel has been checked for fit and it's perfect. One corner needs bending straight (lower right) but that's it. It will be welded in once Geoff has repaired the suspension turrets as access is much easier without it in the way.

Once they're done the panel will be welded back in place and the shell put onto a spit which will make the repairs to the inner and outer rear wings much more straight forward before he moves onto the sills, sunroof cassette and rear window surround. Once the shell is done there are repairs to be done to the bonnet and both doors.

Guy

[SanRemo78]

The rear panel has 6 square holes around the pressing in the centre. I assume that they're for number plate fixings but I'm in two minds about whether to leave them like that or have them welded up. Anyone got any thoughts?

[peteracs]

6 seems excessive when a couple + adhesive double sided pads will suffice for the number plate, or just the pads?

Good progress, nice to see.

Peter

[WestonE]

Just Pads for the number plate. Why risk holes that might chip with plastic inserts going in and rust.

[SanRemo78]

My thoughts too. Six more holes to weld up then!

[SanRemo78]

I've been dismantling parts ready to take for shot blasting and powder coating, subframes and suspension components mainly and I've had a look at the rear transverse arms along with some spare I have acquired over the last year. All the adjustable ones look to be in great condition with minimal surface corrosion and all broke down into component for easily. I'll be replacing the bushes with Mark's poly ones. Given that powder coating is likely to fill the threads I'll do one set with a wire wheel, rust converter and a few coats of paint as an alternative.

The pressed ones are a different matter and have suffered heavier corrosion but are still perfectly usable. I've removed all the bushes in preparation for installing poly bushes here too but looking at the three I have I noted that the pair that came off the car have probably got some damage. On examination they both exhibited a bit of twist at the outer end when placed back to back. Easily cured in the vice with a an adjustable wrench. They then matched the third one I have with no twist along the length. There is a sign of a little more damage though not exhibited by the third one, a very very slight downward bend to the outer ends. I assume this is as a result of someone jacking the car at/near the hub/ARB.

I don't think this is critical to the geometry and I'm not sure if I should attempt to unbend them, it'll take more force than the marginal twist they had to straighten them.

What's the perceived wisdom of this forum and does anyone have a spare pressed arm they'd part with so I can get two sets powder coated at the same time?

Guy

[WestonE]

Hi Guy

Go with 4 adjustable rear links ditching the weak pressed items. This gives you more options for suspension set up including camber and they are much stronger. You will notice the Integrale has 4 adjustable links. Keep your straightest pressed link as a dimension template. This is what I have done.

Eric