:eek: ....:thumb: :d
Printable View
:eek: ....:thumb: :d
Sh"t the bed mate, when you said you had done a little bit of re fabrication on the front end i didnt think it was this much.
Its looking class mate love it.
iain
Cracking update dude!
That is utter brilliance Ade, love your work on this and it's not old fashioned at all. Question is though what about revibing the backend? Or is it staying the same???
Keep the goodness alive. ;)
back end will be modded a little - smoothed boot with VW new style badge bonnet opener. New styled rear bumper and different custom lights.
I'm starting from the front then working down the sides ending up at the back.
I've pretty much finished the bonnet now - under skin to reinforce it is all welded up - just need to work out a bonnet latch mechanism - I've opted not to use bonnet pins.
Off to scrappy's - once I can see out my right eye again (wear goggles people - metal and eyes dont mix!)
seriously impressed ade when i first started reading this and read the words massive kit i sort of hung my head and was a little dissapointed but i will honestly say i will happily take that back and eat humble pie as i like it
wheather i like it or not though i am massivly impressed with the engineering and body work goinging into this any body that slates it obviously doesnt understand it a real credit to you mate and you should be proud
dont fancy doing the body work on my 4x4 do you?
TBH u done some crazy work fella and the front end looks brill! and i never been into kits and converting carbodys but great work mate!
looking good mate can't wait to see it finished
coming along nicely ade.
keep up the good work :thumb:
(05th to 09th March 2010).
As some of you know I was made redundant last week (see club chat for thread) so I've decided to give myself some well earned time off from all that worky stuff and enjoy the next couple of months off. Pros and cons of paid redundancy.
Anyway - 'tis a perfect time to work on the Puntova flat out. Heres what I've done in the last 4 days...
Finished metal working on the bonnet - under side and upper skin taken as about as far as my panel beating skills will allow and are primed ready for joining and skimming with filler.
I'll not be doing this though until the rest of the metal work on the car is complete. So with this in mind and to quote Discovery channels "overhaulin" TV show - its deconstruction time...
started by removing the interior (what was left anyway). And I HATE mice - everything reaks of mouse p1sh. They even got into the roof of the car and made a nest out of the soft cotton sound deadening material behind the roof lining! Dash removed and wiring loom exposed. Never seen so much spaghetti!
http://img.photobucket.com/albums/v1.../stripped2.jpg
http://img.photobucket.com/albums/v1.../stripped5.jpg
http://img.photobucket.com/albums/v1.../stripped1.jpg
All the glass was removed - even managed to remove the windscreen without cracking it!
Then the doors came off - drivers door was fine (the last time I rebuilt the car the pins were replaced with lipped cavvy ones) however the passenger door was a real pig (same as the last time) - and it wouldnt budge. Both doors are rotten so I ended up grinding off the passenger one which gave me a good amount of spare metal for patching up the rear!
http://img.photobucket.com/albums/v1.../stripped6.jpg
http://img.photobucket.com/albums/v1.../stripped7.jpg
With the car stripped internally I removed the suspension and underside. Started with the front
http://img.photobucket.com/albums/v1...stripped12.jpg
the dropped the nose on the ground and jacked up the rear nice and high so I could get to the rear axle and petrol tank (a little precariously balanced!)
http://img.photobucket.com/albums/v1.../stripped9.jpg
http://img.photobucket.com/albums/v1...stripped10.jpg
The exle came off really easily as did the petrol tank although the filler neck retaining bolts on the underside were seized solid!
The petrol tank was shagged and I'm amazed I got any mileage at all! One of the fuel line metal connectors was compeltely cracked and when I tried to remove the fuel line it snapped clean off!
With all but the rear brake lines removed I was now ready to get the shell on the A frames so I could clean the underside...
I bought 2 A frame rotisserie style kits from www.mk2mania.co.uk for £120. They came flat packed and were really easy to weld together
I started by raising the nose back up
http://img.photobucket.com/albums/v1...stripped13.jpg
I then bolted the special bumper bar to the chassis via the existing bumper iron bolt holed. With the front of the car modified the company made custom arms for the project at no extra cost!
I then lifted the shell up (not v heavy at all!) and slotted it into the A frame...which was then bolted
http://img.photobucket.com/albums/v1...stripped14.jpg
At this point I realised Id done it back to front - your supposed to bolt the rear A frame on 1st due to weight distribution however using my handy engine crane I managed to lift the rear of the car high enough to get the rear bar in place and slot the A frame in to position.
http://img.photobucket.com/albums/v1...stripped18.jpg
http://img.photobucket.com/albums/v1...stripped15.jpg
http://img.photobucket.com/albums/v1...stripped16.jpg
http://img.photobucket.com/albums/v1...stripped17.jpg
The car can be rolled a full 180' either side and is so light it can be rotated with one hand!
http://img.photobucket.com/albums/v1...stripped19.jpg
The plan now is to repair the sills and rear 1/4 panels - I'll then lower the car and repair the rear panel...
funking love it
Bare shell FTW! I was wondering if you were going to go this way mate.
Nice frame too. Wish I had the room! Proper job.
Very cool Ade
I've love to strip mine right down like that and get it up on an A-frame!
The pics say it all really. Wish I could do that. Probably have the room but the garage is full of s*it (90% of it not even mine. Grrr! :mad: )
Really can't wait for this to be finished. With such a huge engine bay now, coz of the extended front you could have a big block with a HUGE turbo lol
Wednesday and Thursday 10th and 11th March 2010
The last 2 days I are mostly be chopping off the passenger side sill and replacing it - and what a horror story I found!
I knew the car had had some bodge work done to it in the past and suspected the rear arches had been fibreglassed at some point (noticed this when I resprayed it several yrs ago in Ades Garage v1).
Anyway what I found was scarey!
1st I removed the remaining underside parts - fuel and brake lines, clips etc.
http://www.modelnovas.com/images/passill1.JPG
overall the underside is in pretty good condition considering the state of the arches
http://www.modelnovas.com/images/passill2.JPG
rear suspension mounts look solid enough
http://www.modelnovas.com/images/passill4.JPG
http://www.modelnovas.com/images/passill5.JPG
Both sills however are shot with both mounting points on the passenger one collapsed
http://www.modelnovas.com/images/passill11.JPG
and the drives one had a big patch welded in it in the past
http://www.modelnovas.com/images/passill14.JPG
I started to pick away as the passenger sill and found a HUGE hole in the sill that had been poacked with fibreglass and WOOD!
http://www.modelnovas.com/images/passill15.JPG
http://www.modelnovas.com/images/passill17.JPG
The rear 1/4 was also totally rotten
http://www.modelnovas.com/images/passill18.JPG
I discovered the rear 1/4 was actually secured with fibreglass and rivets!
http://www.modelnovas.com/images/passill22.JPG
Good work Ade, looks like youve got plenty of do!
Jeees man - quite a few surprises! :eek:
it reminds me of the 350z thread.....
its shocking what people will do to get a car sold on.
about 12 years ago a friend asked me to look at a purple sr his son had bought which had a caliper fault. i noticed that it was 2 cars made into 1...... from 10 yards away you could see the lines in the sills where they had welded it up
baaaaahahahaha thats baxter worthy bodging
it all had to go!
Heres a pic of the new panel from Hadrian panels (full sill was £25 inc delivery) offered up to checl for fit...
http://www.modelnovas.com/images/passill24.JPG
Needs a little fettling just on the edges but overall its an excellent fit and lines up with whats left of the original jack piunts really well
http://www.modelnovas.com/images/passill25.JPG
http://www.modelnovas.com/images/passill26.JPG
I then ground down the paint to reveal the spot welds. The new sill will be "plug welded" to where the prev spot werlds were to replicate the fit and the edges that bond to the existing panels will be seam welded. The old welds need drilling out 1st
http://www.modelnovas.com/images/passill28.JPG
The bottom edge of the sill was so rotten I only needed to drill out a couple of welds - the rest just knocked out with a hammer and chisel!
http://www.modelnovas.com/images/passill30.JPG
I then marked up guide lines to where the new panel would go so I could cut the old one out - I left 10mm extra just incase and also to allow for some "lap welding" on the straight sections for added strength
http://www.modelnovas.com/images/passill31.JPG
I then cut the passenger sill off and was confronted with this right next to the passenger seatbelt mounting point!
http://www.modelnovas.com/images/passill32.JPG
http://www.modelnovas.com/images/passill33.JPG
http://www.modelnovas.com/images/passill34.JPG
I removed the wood (which was well and triely secure!) and cleaned up the edges
http://www.modelnovas.com/images/passill36.JPG
well at least that wood be the only part of that Nova body that won't rust. Shocking! Great work though
ade, please keep the wood for the first lighting of the loonaque at the national weekend
You got wood Ade? thats unreal! Who was the cars previous owner? how big was the hole to get that in in the first place!!
removing the sill revealed loads of rotten metal which needed to be removed and new panels welded in place. I spent most of a day patching up inner sill linings and seams to give the new outer panel something to attach to!
http://www.modelnovas.com/images/passill37.JPG
After removing most of the underseal and sound deadening from the sill edges I started work on patching up the passenger seatbelt floor pan area
http://www.modelnovas.com/images/passill39.JPG
This needed 2 sections - one from the floor to the sill and one to the body as well as a new lower section running the length of the rear 1/4 to the arch -
http://www.modelnovas.com/images/passill40.JPG
http://www.modelnovas.com/images/passill41.JPG
new lower section
http://www.modelnovas.com/images/passill42.JPG
http://www.modelnovas.com/images/passill43.JPG
http://www.modelnovas.com/images/passill44.JPG
new rear 1/4 inner section
http://www.modelnovas.com/images/passill45.JPG
These new sections were plug welded to the metal behind them and were ready for the new sill. However I now needed to repair the front mounting section which was more complex because it backed on to the inner front wheel arch. A replacement panel had at some point been welded in there in the past but instead of cutting out the old one they'd just welded fresh metal over rusty - which as we know just rots the fresh metal!
http://www.modelnovas.com/images/passill48.JPG
so I had to cut the "new" metal out to remove what I could of the old and treat what I couldnt get at with krust and sealer
http://www.modelnovas.com/images/passill50.JPG
I then made several replacement panels and rewelded the edges
http://www.modelnovas.com/images/passill51.JPG
Three sections were needed just to strengthen the mounting point
http://www.modelnovas.com/images/passill52.JPG
With most of the inside of the sill repaired (theres a still a small section to do at the front but I need to fit the sill 1st before I can do that) I test fitted the sill again and then cut plug weld holes.
To to this I used a tool called a "joggler" which has a built in hole punch on the back of it. A joggler is like a pair of pliers but it bends metal to form a lip so that when you do a lap weld (which is one bit of metal overlapping another) both panels are nice and flush with one sitting in the groove of the other. The weld then grips both panels making for a very strong weld - the only downside it is leaves a lip on the inside whoch needs properly sealed - however I used weld through primer so a little seam sealer will sort this.
http://www.modelnovas.com/images/passill53.JPG
A pic of the door edge - this is a very fiddley section and needs to line up properly
http://www.modelnovas.com/images/passill54.JPG
everything was gripped tight and I plug welded and ground back the door edge
http://www.modelnovas.com/images/passill62.JPG
front A pillar
http://www.modelnovas.com/images/passill59.JPG
and rear 1/4 panel
http://www.modelnovas.com/images/passill60.JPG
The corner section on the sill was hard to do but came out superbly
http://www.modelnovas.com/images/passill61.JPG
http://www.modelnovas.com/images/passill63.JPG
One new passenger sill
http://www.modelnovas.com/images/passill64.JPG
Theres still the front wheel arch section to finish off and I've also not welded up the lower edge yet - I need to mount the door to ensure the gaps are still level although the replacement sill slotted in to the mounting points smoothly and theres literally no room for moving it!
thats not a bodge, wood is lighter then steel, i can see all the track lads doing it :)
edit, foam is even lighter lol
Quality work Ade :thumb:
ade, check out the rear bumper on this, i know it looks ****e, but with your skill you could make something better
http://www.youtube.com/watch?v=qUn_m...eature=related
good work Ade :thumb:
shocked about the wood lol
Love the roll over jig. Great work on the sill.
nice work Ade i wish i had got that full sill when i did mines as the front jacking point was non existant lol. the roll over jig looks tidy to, do you know roughly how much room is needed to use the jig.
Fantastic work that Ade!
Makes you wonder just how big the hole was to get a fair size chunk of wood like that in there!
tis awesome seeing quality work and showing how things should be done :D
Anyone know whnat the bumper is in the link from Nick?
no idea lol
looks like a clio v6 one to me
Looking good ! Havnt checked back on this in a long time, it's looking alot more professional now, i know exactly what you mean regarding doing something and then coming back to it after a long time and thinking "Why did i do this" ha ha, some very good work now though ! Liking the previous bodge job on the sill ha ha, i've seen plenty of stupid bodge jobs like that before ! expanding foam and filler seems to be another popular one with sills, anyhow good luck with it all and look forward to seeing another update.
I think this build is awsome.
I have a little moto and its short cuts are not always quicker
This pic is what i mean.....................
http://www.modelnovas.com/images/passill17.JPG
It must have taken longer to get that piece of wood in that hole than to do it the right way.
Im glad to see this project is being done propper
Respect to you:thumb: