Dreaded rust

Rust problems and repairs, leaky sunroof... Battery, starter, lights, fuses, airco, heating unit, stereo... | Tuning: custom spoilers & bodykits, fiberglass parts...
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foggyjames
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Re: Dreaded rust

Post by foggyjames » 10 Oct 2011 11:03 pm

Just read through this. Wow...what a heroic effort :)

cheers

James
VOC 300-series Register Keeper
'89 740 Turbo Intercooler
'88 360 Turbo Intercooler
'85 360 GLT
'81 343 GLS R-Sport
'79 343 DL
'70 164
...and some modern FWD nonsense to get me to work...
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Ride_on
Posts: 2265
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on » 10 Oct 2011 11:12 pm

Speedy88 wrote:It's indoors. It can wait. If I were you I'd get all the "lower down" jobs done before it gets REALLY cold. Don't want to be on the floor when the cold starts coming upwards.
I know, did that last year, sitting on cold floor for ages, did not do my ass any good atall. Ended up with underfloor matting down my pants, worked a treat :lol:

Have installed a rad in the garage and just got cavity wall ins in the house/garage, still foor will probably get cold.

As for 'heroic', probably stupid really, but its labour of love.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7
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foggyjames
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Re: Dreaded rust

Post by foggyjames » 10 Oct 2011 11:56 pm

Isn't stupid an integral part of heroic?! Anyone still running one of these cars kinda needs their head examining, so we all fit in well :)

cheers

James
VOC 300-series Register Keeper
'89 740 Turbo Intercooler
'88 360 Turbo Intercooler
'85 360 GLT
'81 343 GLS R-Sport
'79 343 DL
'70 164
...and some modern FWD nonsense to get me to work...
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Ride_on
Posts: 2265
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on » 19 Oct 2011 11:00 pm

Made some progress with this difficult shape.

Repaired the windscreen curve
Let in vertical and horizontal patch to the inner corner
IMG_2892s.JPG
Layer 1
Used carboard template to work out shape for layer 2, aswell as diagrams above to work out what I am connecting, then cut out in metal
Attached layer 2 patch to the curve with mole grips and beat it down to the required curve (not critical as hidden).
IMG_2891s.JPG
Layer 2 cut out and beaten
Still a bit of trmming and shaping, but hardest bit over.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7
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trabitom99
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Re: Dreaded rust

Post by trabitom99 » 20 Oct 2011 07:57 am

Keep up the good work mate, I have so much respect for what you're doing!

Tom
343 GL Touring B14.1E CVT (155) 98000kms 1980 (sold)
343 L Junior B14.3E MT4 (155) 229000kms 1981 (scrapped)
343 DLS B19A MT4 (155) 167900kms 1982
360 GL Injection B200F MT5 (231) 348598kms 1988 (scrapped)
360 GLT B200F MT5 (302) 230000kms 1988
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Chris_C
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Re: Dreaded rust

Post by Chris_C » 20 Oct 2011 08:23 am

I'm really not looking forward to the day I have to do this job. Good metal smacking skills RideOn!
'89(G) 340 GLE B172k
'03 S60 D5 SE, '91 (J) MX5, 1954 Cyclemaster
Ex:
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12; '91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast
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Ride_on
Posts: 2265
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on » 21 Oct 2011 07:02 pm

Chris_C wrote:I'm really not looking forward to the day I have to do this job. Good metal smacking skills RideOn!
Honestly it was easy, I have no bashing skills. Generally I can only repair flat parts, anything with curves or bend I often just weld it in partially then beat it down. Only tools - anvil, shears, claw hammer and mole grips, and lots of grinding equipment. This curve was easy because its just structural internal, no cosmetic aspect. The hard part was knowing what to connect to what because there was so much loss. Anything more complicated I cut from a donor, or weld flat parts together.

If the outer skin is not worth recovering, you can buy repair sections.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7
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MCHUDD
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Re: Dreaded rust

Post by MCHUDD » 24 Oct 2011 09:04 pm

Hi Mate.
Fantastic work. Way above my skill zone.
You deffinatly qualify for a replacement windscreen :lol: :lol: :lol:
Cheers Mark.
sm69 sm69 sm69 sm69 sm69 sm69 sm69 sm69 sm69
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Ride_on
Posts: 2265
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on » 24 Sep 2012 07:19 pm

Some more photos to keep you interested
IMG_2895s.JPG
layer 2 welded
IMG_2896s.JPG
layer 2 finished and starting to add outer skin
IMG_2950s.JPG
State of FL radius arm mounting
IMG_2945s.JPG
skinned and roughly finished
IMG_3070s.JPG
Inner guard repair
IMG_3080s.JPG
Inner guard welded (from Mchudd's car)
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7
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Ride_on
Posts: 2265
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on » 24 Sep 2012 07:27 pm

More older photo's and doing the sill today in anticipation of Macplaxtons arrival with new sill.
IMG_3100s.JPG
Front right footwell reinforcement
IMG_3110s.JPG
Footwell reinforcement ready to weld
IMG_3123s.JPG
Removing RHS sill, drill pilots then cutter
IMG_3127s.JPG
Top detached, after some hacking at the front door hinge area
IMG_3129s.JPG
Sill cut off at the bottom revealing prevous repairs.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7
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Hell Driver
Posts: 1416
Joined: 18 Aug 2009 09:58 pm
Location: Doncaster UK

Re: Dreaded rust

Post by Hell Driver » 24 Sep 2012 07:55 pm

Brave work there!
360 GLE Saloon (D 86)
360 GLS (A 84)
343 DL (W 80) :-)
340 GL 1.7 (G 89)
360 GLS (Y 83)
440 Turbo (J 92)
Transit Tipper 125 T350 (02)Alive Again!
Transit Tipper Smiley face Q reg
Mitsubishi Colt 1.1 (54)
R.I.P. 77 343 DL vario :-(
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Speedy88
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Joined: 04 May 2009 11:52 pm
Location: Bristol

Re: Dreaded rust

Post by Speedy88 » 25 Sep 2012 07:15 am

It's getting there sm4
'88 340 Williams (Sold)
'85 360 GLS - Drift project (Sold)
'77 Colt Sigma
'96 940 Drift project
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trabitom99
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Re: Dreaded rust

Post by trabitom99 » 25 Sep 2012 08:14 am

Well done! Brave man ...

Tom
343 GL Touring B14.1E CVT (155) 98000kms 1980 (sold)
343 L Junior B14.3E MT4 (155) 229000kms 1981 (scrapped)
343 DLS B19A MT4 (155) 167900kms 1982
360 GL Injection B200F MT5 (231) 348598kms 1988 (scrapped)
360 GLT B200F MT5 (302) 230000kms 1988
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thebear54
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Location: Mount Tabor, Vermont USA
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Re: Dreaded rust

Post by thebear54 » 25 Sep 2012 11:13 am

My hat is off to you for doing a proper job of killing the rust.

WELL DONE !!, I am impressed you are taking the time.

John
DAF CLUB of AMERICA Director & DAF MUSEUM-USA Director
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MCHUDD
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Re: Dreaded rust

Post by MCHUDD » 26 Sep 2012 11:04 am

Hi mate.
Job seems to be coming along fine.
I think i was ment to pick up some sills from mac at the beginning
of september for you but they had not been delivered to him
before the meet so i couldn't bring them home.
Cheers Mark.
sm69 sm69 sm69 sm69 sm69
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