Front offside wing repair pt1...

I've been thinking long and hard about this... repair or replace? . . . . . . . Finally decided to have a go at repairing and it looks crap replace IT!

The wings has been off the car for a while now as I still haven't found a suitable inner wing panel yet.

I was thinking back to the days when helping my dad in his wood workshop - he always made a jigs to hold things in place while assembling projects.

So with an old table (out of the green house) I place the wing on top and using some wooden battens as stops and clamps the hold it. I guess with the lip removed the rigidity of the wing will suffer and welding the repair panel in the wrong place would course fit issues later.

I ordered a repair arch from Robsport and lead sticks and solder paint off ebay for filling and repairing the rear lower flange edge.

I clamped the new arch in place and scribed a edge which need to cut back from by 5mm. Both ends of panel will need some work to get it to fit.

4hrs

Spare wheel well...

Like the drivers floor the sound insulation was cracked and the plug was rusty.
I removed the old insulation then replaced the plug and sealed it.

I cut to shape the new sound pad and using a decorating wallpaper roller pushed it into place.

Then a quick coat primer and white gloss the seal until a final coat of body colour later.

2hrs

Rear lower sill...

The rear low sill has some rust holes. I cut out a section and welded in a plate, but as I was cleaning the area up to more holes appeared. Again looking at the donor car both these sections had been replaced with repair panels.

The poor state of repairs on the donor meant it was very easy to remove the one I needed. With only six tick welds holding it in place, this also meant it was already rusting like most of the other repairs done.

I decided as it was on the underside surface, I would patch it after removing the rusty bits and cut a section from the repair panel.

The panel already had rusty areas so I used it as a template cutting a new section form new metal. Clamping in place and then seam welding along the edges.

Using a flap disc on the front edge to get the right profile before welding this part - I don't think your notice the extra thickness once some finishing is done.

3hrs

Boot lid...

Many years ago I had fitted a foam/rubber covered rear spoiler to the boot lid. After a couple of years the damp and water got into it - when we had a frost or cold weather the water would freeze and the ends would curly up!

When I removed it all five drill holes had rusted which needed to be cleaned and welded up. I started by using flap disc on both sides to get a good surface. I drilled out a larger holes to ensure I got all the rust.

Using aluminium strips under each hole I welded them up. I then started to clean off some of the paint and got a bit carried away - ended up doing it all.

I will need to do some filling around the holes later but for now I gave it a quick coat of paint to seal it until I'm ready to do the paint preparation.

3hrs

New sill fitted...

Ok with the lower wing flange repaired - it's time to fit the new sill. With the help of my fellow 'Black Nail Gang' members Pete and Dick and a promise of a BBQ after - Monday of the Bank Holiday weekend was set.

As usual it was p*ssing down, so I put extra cover over the garage doors and setup the gazebo for cooking under.

I had a couple of goes trying a test fit the sill but with three pairs of hands made it easy. Dick brought his new toy a spot welder - which was great and made easy work the top edge. Using the trolley jack and block on the bottom edge we worked along clamping it into position and then spot welded.

Plug welding the A and B pillars and then the inside areas. Finally welding the rear flange of the sill.

Great job and many thanks guys! With the food cooked under the gazebo (still raining) and a few drinks with the ladies it was time for me to say 'now we know how to do it' the other side should be a doddle!

9hrs