RUST!!!!

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Jaspersilus
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Joined: 19 Feb 2009 11:55 pm
Location: Rotherham

RUST!!!!

Post by Jaspersilus » 09 Apr 2012 07:05 pm

Hi Chaps,
well today I removed the front wings with the idea of replacing or repairing them, your opinions would be very welcome!

When the wings were removed unexpected badness was found on the inner wings, dont know how Ill go about repairing them, but does look like there is a seam between the rusty bottom half and the sound top half, is this something that can be bought?

There are rust holes on the front valance, the passenger side sill does appear to need replacing, though the steel behind is still in good condition, the drivers side sill seems fine!

Looking at the wings would you replace or repair ( the passanger side wing also has a crease in it) !

Please comment and advise
cheers Jason

pics here http://photobucket.com/jaspersilusurl

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bogbasic
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Re: RUST!!!!

Post by bogbasic » 09 Apr 2012 11:22 pm

Hello

it is a really lovely car, and the photos have an element of deja vu about them (see below) so I would just bite the bullet, give yourself a couple of years and get on with it....

Good luck. Bests, bogbasic.
1988 340 1.4 GL, 218k, 5 door (Grey Bess). Gone to CBA.
1991 340 1.7 GL, 64k, 5 door, petrol blue (Deep Blue).
1988 360 2.0 GLE, 140k, 5 door, ocean blue metallic (Blue Bess).
1989 340 1.7 GL, 108k, 3 door (Red Ness).
More info here!

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Chris_C
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Re: RUST!!!!

Post by Chris_C » 10 Apr 2012 07:58 am

Yup, looks similar to Fake too...

I'd start with taking out most of the interior (seats, carpet, boot side panels and boot carpet) If my hunch is right, the side where the sill is gone will also have a few issues in the floor pan/seat mounts, as the tiny "L" section that joins the floor to the sill is nearly completely missing in those photos. Secondly, check the rear damper top mount behind those boot plastics, I've a tiny feeling that might be making a bit for freedom too. Last place to check is the cross member under the car nearly above the axle, though I can't remember in a 360 how that varies with the different boot floor.

It's doable, myself and a mate got mine done in three non stop weeks from a position worse in the wings but better in the sills to what you have there, plus floor and rear damper mounts doing.

Pictures from mine are in here volvo.chriscardwell.co.uk though they are mixed up some. Ignore the welding of inner wing, that's on my other one, but then there is a set of sills then a break then a set of the wings as you are doing and sills etc.
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12 - NASLR Time 15.7secs
'03 S60 D5 SE, '91 (J) MX5
Ex:
'91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

Ride_on
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Re: RUST!!!!

Post by Ride_on » 10 Apr 2012 02:49 pm

Yep looks pretty similar to mine, only maybe not quite as bad. I'd say it needs major restoration work, which you can do.

Strip the car out, support the engine+gearbox weight off the chassis (eg prop up with jacks and wood). and remove the doors. Cover the windows inside and out to prevent damage from angle grinder sparks.

Put the car on axle stands on suspension parts.

Remove sills, and rebuild the inner parts, paying special attention to the jacking points, adding strengthening to the original design.
Add new outer sills (available).

Put the rear axle stands on the new rear jacking points.

Strip out the drive and fuel tank and repair the rear box sections and suspensions mounts. Then work round to the front of the car rebuilding the front valence and inner guards.

It will be probably much worse than that it looks, so be prepared, have plenty of rust removal tools and materials as well as breathing, eye and ear protection.

Having said that, it would probably be a much better idea to start with a better shell, like a garaged 340 and use the 360 to rebuild it. They still may need work, but maybe 10% the work, even if you still have to replace the sills, you probably won't have to rebuild the inners.

http://www.volvo300mania.com/forum-uk/v ... 3&start=15
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

Jaspersilus
Posts: 159
Joined: 19 Feb 2009 11:55 pm
Location: Rotherham

Re: RUST!!!!

Post by Jaspersilus » 10 Apr 2012 07:42 pm

Oh God,
cheers guys for the input, if its as bad as you all suspect ( with experience, god damn you :cry: ) then I may just start saving up for a minter and spend extra on complete waxoyl!
Ill spend this weekend searching out rust from all areas and will post pics of every bit I find, Im hoping to find no more, but you re probably right!

I have a limit of about £500 and 5 months to get it done including cost of tools, I have no angle grinder, no welder, no ramps, no axle stands( I reckon about £250 for these)

Can I cut a small section of the sill out with out bracing the car first just to have a sneak peak behind?

Also I have never ever welded anything or cut and shaped sheet metal, engine, steering and suspension I can usually figure out!
Lastly are the bottom sections of the inner wings available anywhere?

Cheers Chaps

Ride_on
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Re: RUST!!!!

Post by Ride_on » 11 Apr 2012 12:33 am

The front wing inners are not available, and quite difficult to rebuild if the outer edge is lost, I use parts cut from a good car. Still difficult to marry it up.

Many cosmetic rust repair are available (Sills, wheel archs, window corners, door skins), but not front valence or inner sills (often needed). If you are very lucky you might pick a valence/front panel up on ebay.

Without experience of major welding work you probably do not want to put alot of effort into a car that may not turn out that well. I had a few failed attempts at major work before this car, luckily at the time there were plenty of good cheap 360s around, so I stopped wasting my time. To be honest on this car I am now starting to correct some of my early work. I pretty much had to repair every typical rust spot.
Attachments
IMG_3033s.JPG
Snap
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

Jaspersilus
Posts: 159
Joined: 19 Feb 2009 11:55 pm
Location: Rotherham

Re: RUST!!!!

Post by Jaspersilus » 11 Apr 2012 08:23 am

Yes mate,
lots of the outer edge is rusted away, so Ill have to find a donor car, may even have have to employ someone to weld it for me, maybe cheaper than buying all the welding gear anyway?
But will strip the car further this weekend to find more rust!
Cheers Jason

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Chris_C
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Re: RUST!!!!

Post by Chris_C » 11 Apr 2012 09:10 am

FWIW, when I did that same part, I took a cornflake packet, ran it down the passenger side (which still had the piece that I was missing on the drivers side of that outer edge) then cut it from the box, flipped it and offered it up. I then cut it out of 0.8mm, tacked it in place to the edge of the rust (not pretty, but it'll hold). Then build up from the inside of the car to the new bit of metal so it's supported, then cut the rust off it each side, every time following the process of:

cardboard template
cut out rusty bit
transfer template to metal
make metal fit hole
make metal fit hole again
still make metal fit hole

If your patch is spot on to your air gap, you need a lot less ninja skill in the welding department. In all three dimensions too.
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12 - NASLR Time 15.7secs
'03 S60 D5 SE, '91 (J) MX5
Ex:
'91(H) 340 GL B14.4E - Kar; '88(F) 360 GLT B200E - Jet -> BKV 300 Runner Up 09; '89(G) 360 GLT B200E - Beast

Jaspersilus
Posts: 159
Joined: 19 Feb 2009 11:55 pm
Location: Rotherham

Re: RUST!!!!

Post by Jaspersilus » 11 Apr 2012 12:56 pm

Cheers Chris,
I think that will be my only option, I can deal with it in time, just hoping that the weekends rust finding is a failure cos when I pulled it out of the barn 2 weeks ago I thought my jobs would be new springs, new shocks, new brake pipes/lines and calipers, new bushes and perhaps some new steering parts :shock:
but now the big issue is rust I didnt suspect, apart from the front wings and sunroof I thought all was good, its not :cry:
Cheers Jason

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Chris_C
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Re: RUST!!!!

Post by Chris_C » 11 Apr 2012 11:33 pm

Most "mint" car's I've seen have a lot hidden. Just be methodical, and take pictures along the way. You can be doing what feels like the same bit for a day and not feel to have got anywhere, but looking at a before and after reminds you just how much you have done.
'89(F) 340 GL F7R (ex B172k) - Fake -> SBKV 300 Runner Up 08, 12 - NASLR Time 15.7secs
'03 S60 D5 SE, '91 (J) MX5
Ex:
'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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