Project Down n' Out

so heres my little project, to fix the rust add a lick of paint and drive the thing!

First thing if to sort out all the rust! If some of you seen my post in the chat section then you would know about my rear arches and front inner wings…

Day 1

whilst i was messing about with my engine, paul_c Showed up!  

He deffo knew what he was doing and got stuck in straight away! attackin the rust with powertools :mrgreen:






After a couple of hours welding in the blazin sun the first bit of welding was done! Paul has kindly lent me his welding equipment which means i can get stuck in on weekends and weeknights…

Thanks for the equipment paul, thats a big help!

I'll post my days progress later on.. 8)

Good to hear you haven't set fire to yourself yet. Hopefully in a couple of weeks your wing will look like this!

…just about!!! that underseal loves to catch fire eh???


8O Paul that looks mint!!! 8O

heres my patch work….

dont laugh!!  









and the finished rear section…



Looks ruff but it doesnt bother me…aslong as theres no rust!…i could grind the welds down but after slapping loads of new underseal on you might not see them!?

anyway thats my first days progress!! let me know what you think :dontknow:  8)

I guess it was easier than you thought :wink:

I bet now you know what to do you'll wanna go over the whole car! 8)

Good work 8)

Get in there Low Thats what we like to see

:clap: glad to see you didn't give up on her

that your first time welding? not as hard as you'd think is it?  :wink:

should be good for another 10-15 years when your finished

Well done there matey keep up the good work :clap:

cheers lads, yea im finding it very easy!  thanks for the comments

Progress is gonna be very slow now as i lost my job so i got no income at present… :evil:

Made some progress today but didnt take any pics!!!  until the gas ran out so im getting it refilled tomoz…

Just waiting for my front inner wing panel to turn up so i finish the n/s then start on the o/s :roll:

Did get pictures of my new tyres tho



low'

those tyres are mental!  8O

215/40 on a 9.. i'll get a better pic 2 moz of what kind of stretch that looks like    8)

nice stretch dude , what wheel  , offset combos u runnin

Do you reckon it'll be ready for the next NWM? :dontknow:

cheers for the comments

the wheels are 14x8/9 with stretched rubber

phataz nah mate i doubt i'tl make any meet for a while yet!! :roll:

anywayz here my update for today

removed the rusted part of the rear o/s inner wing, still waiting for my repair panel to show up for hadrian panels!! :evil:





this was after i finished it, its took my all day as its a very orkward place. I first try'd to patch it with 1 piece but as the angles of the original peice is all over the place i had to make my own using 3 parts! got very stressed but it was great fun! :mrgreen:  i then used sealent over it so it looks good and you cant see the welds!

theres only 3 more holes on the drivers side which im planning on patching tommorw, in this picture you can see that the whole wing is rotten but not to the part where its rusting, im thinking about covering the wing in por-15 to prevent rust?? paul whats your opinions?

Great work mate, your welding's looking better than mine! I've no experience of the POR15, is it one of those rust converters? Whichever coating you use (zinc based primer, or POR15, or Stonechip, or Underseal) directly onto bare metal, I'd be tempted to run over the entire area with a grinder-mounted wire brush, this way at least its going to remove the majority of the actual surface rust and do a good try at getting into the pitting.

For general info, but probably not so wise in this scenario, it would be better to lightly grind the surface to remove all the pitting. The problem you have here, is that it would weaken the metal. So its alright for small areas and non-structural areas, but probably not the entire inner wing. So I think in this scenario I'd use either zinc-based primer or POR15 (or red oxide???), then give a good thick coating of alkyd-based stonechip (its like a rubbery thick matt paint, unlike bitumen-based underseal).

Best tip of all, would be to fit wing-liners, eg from later models. I got mine from the VW Dealer when they did a search on cabby (may have been caddy) parts.

cheers paul, yea i've got a big tub of that underseal stuff from halfords, i remember using some on my old golf and i wasnt very happy with it then!! it stayed soft and even after a week of drying mud and dirt was stuck to it…dunno why i bought it again!!

where can you get some of this  stonechip from? i think i'll go with that idea, i've seen a few good read ups on por-15 as rust preventing.. so i'll get rid of all the flacking rust and cover it with that, then re-cover with stonechip…

also where do you get that sealent from..errr i've ran out!! :wink:  :mrgreen:

yea im gonna be on the look out for some wheel liners, how much were they from the main stealer then?? ?300??..4?

may have to modify them abit…dont want them takin chunks outta my tyres!!

update:

seen as the front panel was caked with holes…i decided it had to go…





what have i got myself into…

seen as its like this im gonna take the engine out and do a 16v conversion…..  :roll:   :twisted:  :mrgreen:

good luck mate, you are braver than I am!

i really do admire people for putting in the hard yards!

Cheers, A.

cheers mate! i havnt got any idea what im doing..just going with tha flow

i was gona leave it at first n just patch all the holes but thought nah…..then put the grinder through the middle of the the support so there would be no turning back!!! :mrgreen:

some good work there, you'll feel pleased with yourself when you put the new front end on  :y: