Dreaded rust

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foggyjames
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Joined: 29 Jan 2004 04:20 am
Location: Nottingham, UK

Re: Dreaded rust

Post by foggyjames »

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: 2266
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on »

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 »

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: 2266
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on »

Made some progress with this difficult shape.

Repaired the windscreen curve
Let in vertical and horizontal patch to the inner corner
Layer 1
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).
Layer 2 cut out and beaten
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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Location: Bonn, Germany

Re: Dreaded rust

Post by trabitom99 »

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 »

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: 2266
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on »

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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Joined: 18 May 2006 03:43 pm
Location: BELFAST UNITED KINGDOM

Re: Dreaded rust

Post by MCHUDD »

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: 2266
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on »

Some more photos to keep you interested
layer 2 welded
layer 2 welded
layer 2 finished and starting to add outer skin
layer 2 finished and starting to add outer skin
State of FL radius arm mounting
State of FL radius arm mounting
skinned and roughly finished
skinned and roughly finished
Inner guard repair
Inner guard repair
Inner guard welded (from Mchudd's car)
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: 2266
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: Dreaded rust

Post by Ride_on »

More older photo's and doing the sill today in anticipation of Macplaxtons arrival with new sill.
Front right footwell reinforcement
Front right footwell reinforcement
Footwell reinforcement ready to weld
Footwell reinforcement ready to weld
Removing RHS sill, drill pilots then cutter
Removing RHS sill, drill pilots then cutter
Top detached, after some hacking at the front door hinge area
Top detached, after some hacking at the front door hinge area
Sill cut off at the bottom revealing prevous repairs.
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: 1417
Joined: 18 Aug 2009 09:58 pm
Location: Doncaster UK

Re: Dreaded rust

Post by Hell Driver »

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
Posts: 4057
Joined: 04 May 2009 11:52 pm
Location: Bristol

Re: Dreaded rust

Post by Speedy88 »

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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Posts: 4398
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Location: Bonn, Germany

Re: Dreaded rust

Post by trabitom99 »

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
Posts: 227
Joined: 02 Oct 2011 12:13 pm
Location: Mount Tabor, Vermont USA
Contact:
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Re: Dreaded rust

Post by thebear54 »

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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Posts: 2537
Joined: 18 May 2006 03:43 pm
Location: BELFAST UNITED KINGDOM

Re: Dreaded rust

Post by MCHUDD »

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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