Fuse's 360GLT

[Fuse]

There's progress.

I headed to my friend's place for few days and we did some work on the car.

First step was to roll the car out from the barn. It had collected a bit of dust during the winter.



Some washing and we found a 300-series under the dirt.





At first I was way too optimistic and I started to take out the spot weldings on the sills...



Which turned out to be a waste of time as there wasn't too much to save. Angle grinder was the proper tool.



The 2-pillar lift was a bit problematic when working with the sills and the floor around the sills so we manufactured improvised drive-ramps (which turned out to so well that those will be used in future too ). We lifted the car on to the ramps and then we could push the car past the lift's pillars.





Sorry sight.. Sills were replaced at a shop at 2006 but as it turned out those were welded partly over the old sills and inner sills were completely untouched, it had rotten everything inside...




This time everything comes out. More cutting.



At some parts of the floor there were four layers of different patches from different era on top of each other...




After a lot of cutting and thinking, things started to look better again.





We got the driver's side sills and floor pretty much done. Small parts of the outer sill was left unfinished but the driver's side is mostly completed. Next it's the same thing for driver's side. And after that both rear arches so there's still a lot to do but at least there's finally progress and light at the end of the tunnel!


-Marko

[macplaxton]

Great progress there Marko!


There's a dead image link at the end to 4470.

Could only find the big version :

[Chris_C]

Flipping heck Marko, that's scary!

You've removed a chunk of strength from that sill, make sure everything is still level (and the bottom of the C and A pillars are the same distance on that side as the other) when you glue it all back together.

[Ride_on]

Good going. I think the shell is not too stressed sitting on the wheels, but do be careful if/when removing the top of the sill at the door. Maybe support the engine and gearbox to take the weight off.

[Fuse]

Thank you macplaxton! I fixed the dead link.


Everything is in line within 0,5mm (measured, which is pretty well considering the fact that there was no inner sill structure intact before and the whole floor was rusted apart from the sills). We didn't cut out the top section of the inner sill reinforcement structure (only section which was intact actually) and the car was standing on wheels, not on jack stands or similiar. There's no need to cut out anything above the welding line anymore as those structures were intact.

Might seem like a major job but actually that's quite "little" amount of rust in "Finland standard" compared to some 200-series projects I've witnessed where whole floor and everything between the door line and cardan tunnel had to be cut out and replaced. We also did the cutting in sections and welded in a 30x50mm beam between the front and rear arch, before cutting out the floor, then we welded the floor sections on to that beam and welded the inner sections of sills on to that beam. So everything is in correct dimensions.

Of course we also replaced the inner sill structure, though without the cut out holes and beveled reinforcements, but with the 30x50mm bar binding the front and rear section of the car, it's solid enough. Outer sill is still under construction, half of it was finished though I didn't take any pics.



(Don't mind the rust on doors, cosmetical stuff will be dealt with later... )

[trabitom99]

Wow, what a lot of work! But I guess that's the only way to do it ...

Cheers

Tom