looks challenging that, your doin well, those 4 spokes are ace
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looks challenging that, your doin well, those 4 spokes are ace
hi mate
good progress. i noticed you had some problems with the splash guards. When i was sorting mine i found the splash guards to be corroded which led to water leading into the interior and causing a few holes. I basicaly had the interior holes welded up along with the splash guard. The reason im saying is because your doing alot of work to the car and if you check under the carpet and the drivers side inner panel youll see corrosion and its probably best to sort this just now. btw its a pain in the backside to sort! good luck.
cheers
craig
cheers matey - had checked and the inner walls are fine (unlike my other Nova project - had to get new splash guards made!)
Friday 11/07/2008.
Didnt get too much done today due to viewing a new house (which was stunning) but mamaged to get a couple of hours in tonight.
Spend most of the evening adjusting the inner arch to fit the outer one.
Started by cutting the outer skin to the right size. I left a little extra just incase and offered it up for sizing. It's a really good fit -
http://img.photobucket.com/albums/v1.../DSCF00011.jpg
http://img.photobucket.com/albums/v1.../DSCF00021.jpg
I then had to modify the lower corners. As you know I used another outer skin for the inner skin so to make them fit I needed to cut some material away from one of the edges, push it back a bit and weld it up. now it fits perfectly.
The next task was to run a line around the outer panel to get a perfect fit line-
http://img.photobucket.com/albums/v1.../DSCF00031.jpg
I can now grind away the excess metal from the body to get a perfect fit onto the existing panel.
Unfortunately by this time it was 9pm so a tad late to start grinding.
So I decided to finish off one of my front wings. One of them is brand new so has no inner protection except for the black factory primer. I'd applied a coat of chassis black to the whole of the inside earlier in the day and finished by applying a nice thick layer of shutz. the other wing already had a generous amount of shutz applied.
http://img.photobucket.com/albums/v1.../DSCF00051.jpg
Got this off ebay (3 for £7) its designed to be sprayed but can be painted easily enough. I actually bought some proper applkicator nozzels to use with my spray gun but couldnt bloody find them!
10 mins later and the wing was fully protected! You cant really see it from the pic though...
http://img.photobucket.com/albums/v1.../DSCF00061.jpg
Saturdays game is to get up early (he says!), finish the engine bay/wing area and then start the rear arch. If that one goes well I'll start the other side - after I;ve patched up the holes in the boot area...
Ade
Your cracking on with it mate
Once its done we'll need to get another meet organised :)
I agree - hoping to have both arches and rear sorted by this weekend...
Nice one mate
Mine could go with new arches as well, no point just now really - Just had the both rear 1/4 panels painted
looks good mate, you've got a fair amount done recentley too hey, looks like good work.
Top skills Ade.
Its getting there :)
How come the thread title says "1.2sr" ? Lol
Saturday 13/07/2008
Spent most of today skinning the outside of the rear arch.
Started by etch priming the inner arch and then once that weas dry I gave it a nice thick smear of seam sealant.
I then tack welded the outer arch in place.
http://img.photobucket.com/albums/v13/danga/DSC0001.jpg
I welded it in small sections and moved about the length of the arch to stop it warping-
http://img.photobucket.com/albums/v1.../DSc0003-1.jpg
Once this was done the grinder was put to work -
http://img.photobucket.com/albums/v13/danga/DSC0009.jpg
I used a welding joint called "butt welding" where you basically just butt one bit of metal up against another and run a weld down the middle, however my welding skills are still basic and my grinding skills although cautious need to be adjusted slightly to compensate for my welding. I had a couple of thin patches that needed further welding and I spent a fair amount of time shining a torch down the back looking for gaps and cracks.
The hardest part was the filler area - grinders can be brutal in difficult places-
http://img.photobucket.com/albums/v13/danga/DSC0010.jpg
I needed to cut away the extra metal in the middle-
http://img.photobucket.com/albums/v13/danga/DSC0011.jpg
This was then joined to the inner arch.
Later I etch primed the outside and left it to cure overnight ready for a skim of filler. no matter how hard I tried I did get a little but of warping - thankfully though it actually caused the new section to bow inwards just slightly meaning I have a perfect line to the arch lip ready to receive a nice flat skim of filler!
http://img.photobucket.com/albums/v13/danga/DSC0020.jpg
continued...
I then started work on the rear. When I took the bumper off I noticed rust patches and a few holes. At some point in the cars history the rear end has been patched up and theres a few plates in the boot. Something I was aware of when I bought her. What I didnt know though was the person who did the job just welded straight over rusty metal and didnt seal it properly underneath. As such it spread...
Here's pics of the rust areas cut out (the green stuff is rust remover)-
inner arch (the one I'm working on)-
http://img.photobucket.com/albums/v13/danga/DSC0012.jpg
rear chassis leg under the rear light-
http://img.photobucket.com/albums/v13/danga/DSC0013.jpg
rear minus rusty areas -
http://img.photobucket.com/albums/v13/danga/DSC0014.jpg
http://img.photobucket.com/albums/v13/danga/DSC0015.jpg
http://img.photobucket.com/albums/v13/danga/DSC0016.jpg
http://img.photobucket.com/albums/v13/danga/DSC0018.jpg
this is the worst bit-
http://img.photobucket.com/albums/v13/danga/DSC0019.jpg
Also noticed a hole on the drivers strut mount-
http://img.photobucket.com/albums/v13/danga/DSC0021.jpg
http://img.photobucket.com/albums/v13/danga/DSC0022.jpg
They look far worse than they are - nowt a few plates and a bit more welding wont sort!
That's Sunday's task..
I also took a trace of the rear boot lettering and will get it drawn up properly ready for making transfers...
Cracking work rate Ade
Hows the other Nova coming along ?
it's on "hold"...
Gonna wait till I've moved house. once I've finished the white ones repairs I need to pay the wife some attention - shes made a few "comments" of late.
Sunday 13/07/2008
I've got 1 day left after today to finish sorting out the current work on the SR. promised the wife it would be done by Tuesday 9although I'm off work Wednesday so can complete it proper then.
Here's the list of things I've got to do -
Last bit of welding
Make a patch between new arch and existing sill along the bottom (5 min job). Etch prime and seal ready for painting.
Front end
respray one of the wings after it got "knocked" :mad:
Prime and spray drivers inner wing after welding and paint passenger inner wing
Refit the radiator and fan
refill coolant
put coil, washer bottle back in place
reattach vin tags
fit lights
refit the wings and seal in place (fitting indicators and ariel in process)
Rear end
chassis black the underside around the newly sealed areas
Prime and spray white the interior welded areas
Arch
Trim back excess off lip and seal inner lip to outer lip
Drill hole for third screw on fuel filler
Chassis black and shutz the inner arch
chassis black the inside of the 1/4 panel
Waxoyl the inside of the outer arch (I cant get at the outer arch welds from the inside but need to seal it somehow).
Finish sanding and smoothing the skim of filler applied to level the old and new panels.
Speckle coat and check for low spots.
Level and seal with stopper
Remove all vynal to the door edge and along bottom
scotch the rear 1/4 panel
Remove rear window and treat small rust patch
Mask, prime and spray rear 1/4
Other tasks
Refit fuel filler neck
Replace fuel sender and return pipes (cracked and worn)
Reassemble interior (although this isnt essential just now)
Wash car
Move stuff out of next doors garage!
So not much then!
:eek:
Sunday 13/07/2008
Here's what I did today.
In the garage for 8am and started by making templates for the new patch panels for the rear end.
An hour or so later here's the panels cut out-
http://img.photobucket.com/albums/v1...a/DSCF0065.jpg
http://img.photobucket.com/albums/v1...a/DSCF0066.jpg
Here's the holes they need to fill (this pic shows plate one held in place) -
http://img.photobucket.com/albums/v1...a/DSCF0067.jpg
In this pic there are 2 plates - 1 goes on the top and one goes underneath the rear light. They join to the chassis rail and then to theother parts of the car.
Hole from inside the rear arch-
http://img.photobucket.com/albums/v1...a/DSCF0068.jpg
Heres the first plate held ready for welding -
http://img.photobucket.com/albums/v1...a/DSCF0069.jpg
The top hole plugged-
http://img.photobucket.com/albums/v1...a/DSCF0070.jpg
Heres the second plate welded in place-
http://img.photobucket.com/albums/v1...a/DSCF0071.jpg
The next task was the rear holes on the bottom of the car. these were a biatch because the amount of sealer used initially kept catching fire - even though I thought I'd removed it!
First plate held in place -
http://img.photobucket.com/albums/v1...a/DSCF0073.jpg
From the inside - a nice fit -
http://img.photobucket.com/albums/v1...a/DSCF0074.jpg
Welded in palce - my welds are getting better - had some good runs on this one...
http://img.photobucket.com/albums/v1...a/DSCF0075.jpg
continued...
continued...
Then the other side was done. Both panels were welded from the inside aswell for extra strength. Here's both jobs complete-
http://img.photobucket.com/albums/v1...a/DSCF0076.jpg
A coat of etch primer after they tops were ground off the welds to level them-
http://img.photobucket.com/albums/v1...a/DSCF0077.jpg
Once dry the all the welds were sealed.
http://img.photobucket.com/albums/v1...DSCF0079-2.jpg
I also repaired the small hole next to the front strut on the drivers side.
I then started on the filler. Started by applying a generous layer of paste all over the arch. It looks messy and theres more than I need but it'll be sanded back and levelled.
http://img.photobucket.com/albums/v1...a/DSCF0063.jpg
I also finished off the fuel filler hole that needed a few more welds from the inside. this was a real biatch to do. It needs a skim of filler to level it but I'm pleased with the result considering the mess it was in before hand!
http://img.photobucket.com/albums/v1...a/DSCF0078.jpg
Plan to get up at 6am tomorrow to get a good start. Based on the list above I think I;m gonna need to plan it carefully...
My knees are killing me from crouching down so much and my hands are really sore. I also seem to be covered in random burns, scratches and cuts... typical!
Good repair work Ade:thumb:
yopur not doing too bad there mate.
its very hard to just keep going on jobs like that for hours/days on end..
as you say............burns....sore knees...sore back......scratches...cuts etc etc....
usual all part n parcel.
irts hard work .....but u'll get there in the end
I would love to pick your brains lol Seems yours is just like mine! All the same rot places. Top job! :thumb:
good work and top write up ade, really imformative/helpful
Can I joinj the club of the rot spot Nova's lolQuote:
Originally Posted by AW06
Nice work Ade, love your documenting :thumb:
Monday 14th July 2008
Got up early (6am) to start work on the car. had to get rear sorted today.
Started by sanding back arch.
http://img.photobucket.com/albums/v1...a/DSCF0083.jpg
http://img.photobucket.com/albums/v1...a/DSCF0082.jpg
Initially came out well but there were some high spots so I applied another skim of filler and sanding back. I then applied a layer of "stopper". This is basically cellulose putty which is like very fine filler (like very thick paint). you spread it on and it seals the filler (which is pourous and has pin holes of air bubbles in it which can cause problems with paint).
http://img.photobucket.com/albums/v1...a/DSCF0099.jpg
http://img.photobucket.com/albums/v1...a/DSCF0100.jpg
Whilst this cured I removed the rear 1.4 panel window. i notices a rust spot where the 1.4 frame had rubbed the paint.
http://img.photobucket.com/albums/v1...a/DSCF0092.jpg
This would also make spraying the rear easier. the rust spot was treated.
Whilst the stopper cured I also changed the fuel return and sender pipes.
My old ones were badly perished -
http://img.photobucket.com/albums/v1...a/DSCF0094.jpg
For reference the full sender is bigger then the fuel return (I think 6mm and 4mm diameter).
New ones in place-
http://img.photobucket.com/albums/v1...a/DSCF0113.jpg
I then sanded the stopper back using fine wet and dry paper.
http://img.photobucket.com/albums/v1...a/DSCF0103.jpg
The whole panel was then sprayed with zinc primer.
http://img.photobucket.com/albums/v1...a/DSCF0107.jpg
http://img.photobucket.com/albums/v1...a/DSCF0106.jpg
continued...
I masked off the rest of the car leaving the rear 1/4 exposes and gave it several coats of white primer.
http://img.photobucket.com/albums/v1...a/DSCF0108.jpg
To speed up the drying process I used a heat lamp
http://img.photobucket.com/albums/v1...a/DSCF0118.jpg
Whilst this was curing i reassembled the engine bay area. i needed to refit the radiator, refill the coolant, reattach the lights as well as weld up the hole under the drivers strut mount...
http://img.photobucket.com/albums/v1...a/DSCF0089.jpg
I also applied a little paint to the strut tops to make the bay look a little tidier.
Once the primer was cured I flatted it back using 800 grit and then applied some high build primer in some areas I wasnt happy with.
http://img.photobucket.com/albums/v1...a/DSCF0110.jpg
This was cured further using the heat lamp and then a final coat of primer was applied.
Whilst that was curing I poked about uinderneath. I noticed whilst replacing the fuel sender/return hoses that there was a fair amount of rust hidden behind old underseal. I started to pick away...I wish I hadnt...
http://img.photobucket.com/albums/v1...a/DSCF0120.jpg
there were holes!
I left these for now and
went back to sanding the final layer of primer back uwing 800 grit. I did these last couple of stages using the paper soaked in a dilyuted mix of hot water and washing up liquid. this helps keep the panel greese free and the paper clog free.
http://img.photobucket.com/albums/v1...a/DSCF0115.jpg
http://img.photobucket.com/albums/v1...a/DSCF0117.jpg
The panel was then thoroughly dried and the area masked off for the final time.
I then sprayed the rear 1/4 panel using 3 full cans of glazier white.
http://img.photobucket.com/albums/v1...a/DSCF0124.jpg
http://img.photobucket.com/albums/v1...a/DSCF0123.jpg
After a couple of hours and some seady application with the heat lamp the outcome was really good. It needs flatting back but I'm happy with the results...
http://img.photobucket.com/albums/v1...a/DSCF0125.jpg
http://img.photobucket.com/albums/v1...a/DSCF0126.jpg
continued...
I then had to reassemble the front of the car.
I carefully fitted the wings -
passenger
http://img.photobucket.com/albums/v1...a/DSCF0097.jpg
driver
http://img.photobucket.com/albums/v1...a/DSCF0098.jpg
making sure the front edges were sealed with the slam panel.
I then refitted the bumper
http://img.photobucket.com/albums/v1...a/DSCF0128.jpg
I need to redo this because for some reason it wont sit flush the the ends of the wings (both sides) - the side clips are slipping for some reason...
I then sealed the gap between the inner and outer arches and applied a healthy amount of seam sealer all along the inside of the arch and down the join by the filler neck...
The next task is to sort out the rust underneath the car...those holes were right on the sill...
Saturday 19th July 2008
This weekend I planned to cut out the rust and holes I discovered under the floor pan by the drivers sill.
http://img.photobucket.com/albums/v1...a/DSCF0119.jpg
http://img.photobucket.com/albums/v1...a/DSCF0120.jpg
http://img.photobucket.com/albums/v1...a/DSCF0121.jpg
I removed the seat and carpet and it didnt look too bad from inside but I knew it was paper thin-
http://img.photobucket.com/albums/v1...DSCF0001-1.jpg
http://img.photobucket.com/albums/v1...DSCF0002-2.jpg
http://img.photobucket.com/albums/v1...DSCF0003-2.jpg
In addition it looks like Vauxhall in their wisdom thought it'd be okay to shrimp on the rust proofing underneath...
http://img.photobucket.com/albums/v1...DSCF0007-2.jpg
http://img.photobucket.com/albums/v1...DSCF0006-2.jpg
After cleaning off wehat was left of the rust proofing underneath to find good meetal and then cleaning up the inside to do the same I marked out the area to be removed -
http://img.photobucket.com/albums/v1...DSCF0005-3.jpg
continued...
continued...
I ensured the fuel lines were tied well out of the way (see above pics and red tie backs) and brought the grinder out to play
http://img.photobucket.com/albums/v1...DSCF0011-2.jpg
http://img.photobucket.com/albums/v1...DSCF0010-1.jpg
http://img.photobucket.com/albums/v1...DSCF0008-2.jpg
I then made a card template and cut the new sections out of an old wing -
http://img.photobucket.com/albums/v1...DSCF0009-1.jpg
After cleaning up and removing the paint I fettled it so it was a good fit. The new panel will be an l shape with the L section bonded to the sill, and the rest filling the gap - it will be seam welded to the top edge of the sill and around the existing hole then seam sealed flush from underneath after getting a good dose of etch primer.
One of the new panels fettled in place
http://img.photobucket.com/albums/v1...DSCF0012-3.jpg
And then tack welded it in, fellting as I went to ensure a solid fit -
http://img.photobucket.com/albums/v1...DSCF0013-2.jpg
By this time it was 6pm and time for Tea!
Sunday 20th July 2008
More welding today - much to the disgust of the missus who made the comment - "I thought this car was rust free and was your daily runabout that you werent ever ging to mess with!"
I promised I'd be finished by 12pm so I could do stuff with her for the rest of the day - which would have been the case if I hadnt run out of wire mid way through!
:mad:lol
Anyway - managed to wangle more wire and finished the welding up -
http://img.photobucket.com/albums/v1...DSCF0015-4.jpg
http://img.photobucket.com/albums/v1...DSCF0016-2.jpg
http://img.photobucket.com/albums/v1...DSCF0017-2.jpg
This was cleaned up, etch primed (inside and out) and seam sealed...
http://img.photobucket.com/albums/v1...DSCF0019-4.jpg
http://img.photobucket.com/albums/v1...DSCF0020-3.jpg
http://img.photobucket.com/albums/v1...DSCF0018-4.jpg
Once this had cured ther outside and underside were painted with chassis black. prior to this the underside had been doused with rust remover
http://img.photobucket.com/albums/v1...DSCF0021-3.jpg
All I need now is to shutz the underside and then check the passenger side - but thst can wait a week or three...
:p
top work matey :thumb:
No progress then??? lol
Coming on quick as per usual.
Keep up the good work.
Good work mate
You bringing it along to the meet ?
great work there pal, good luck on the underneath it looks pretty nasty!
top work there, turning out to be quite a project lol I scrapped my SR with less rust than that, wish I could weld as i would be doing the same as you :thumb:
excellent work mate, good to see that people still belive in repairing rather than just giving up and finding a new shell
+rep, personnaly id rather repair what i have so i know its good than buy something else that will 9 times out of 10 need something doing anywayQuote:
Originally Posted by novacabrio
more really good work ade, i know what you mean about running out of wire tho, i did last week then yesterday ran out of gas lol and it always seems to be when your making great progress
some good work as per usual mate! yeh as said above it's good to see that someone is welding up as if everyone keeps thinking nah i'll get another shell theyre rapidly gonna run out. Ade have you been doing all the paint with spray cans ? hows it come out if so? how long do you think it's gonna take to be on the road then?
Awesome work Ade.
Good stuff for finding more rust and not letting it get you down, you just crack on with the welder :)
The cars on the road - it's my daily runner so HAS to be. Was only off for 5 days for the rear arches and that was because it was a bigger job than I had planned for.Quote:
Originally Posted by DW-Nova
Used spray cans for all the repair work and it came out really well. Some light orange peel effect but I applied about 3-4 coats so nothing a light sand back with 1000grit (wet) and then a good polish wont cure. It's white paint to 100% forgiving - the best colour (apart from jamaica yellow) for flatting back.
I'm SO glad I bought a welder before Christmas - best investment I ever made! The red project was good to practice on and I'd like to think my welds have improved 100% since the early days, Hardly blow any holes in the metal I'm welding. if I do I know how to handle them.
All I need to do to the SR is repair the other arch (although that's it's in pretty good nick at the moment just the inner arch is shot), fit GSi brakes, touch up some rust spots on the doors (outer skin chips mostly) and then finish shutzing the underside and arches. Then just waxoyl the whole thing ready for winter...
Hilariously my new arch actually buffy on my 14's theres so much lip! lollollol
rust doesnt bother my that much now - as long as it's not one of the major chassis rails - actually look forward to it. the only bit that bugs me is that I need to get a bigger gas bottle and the missus moaning at me for working on the car and not spending time with her!Quote:
Originally Posted by Adam
:roll:
So its about done mate :)
You bringing it along to the meet ?
Happens to us all I think lol well mine certainly does too :mad:Quote:
Originally Posted by ade