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Post by Zed. on Jun 22, 2022 20:40:48 GMT
I'm thinking Mk1 Cavalier/Chevette saloon my Chevette Hs * is sorta in the garden below the remains of a tarpaulin awaiting attention, only had it ~20 years....... no photo's as it's embaressing  Rich. * = remains & not realy origonal rallycar project  |
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Post by Bilbo on Jun 23, 2022 17:45:39 GMT
Noooo, don't run old and rare stuff through winter! Especially not something knocked out in this fair isle! lol I need to deal with the rust that is all over mine, except I am scared that once it starts getting cut away, all I'm going to be left with is a bare chassis, a dashboard, and engine and a seat...  LOL Haha, plan is to buy a clean shell, underseal and cavity wax the hell out of it, and run it as a daily. Will be mint, and a bit of fun rather than some dull modern box. Yeah it's horrible finding more rust, found a fair bit today actually! |
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Post by Bilbo on Jun 23, 2022 17:46:42 GMT
I'm thinking Mk1 Cavalier/Chevette saloon my Chevette Hs * is sorta in the garden below the remains of a tarpaulin awaiting attention, only had it ~20 years....... no photo's as it's embaressing Rich. * = remains & not realy origonal rallycar project I would say I'd have it off you, but it's not a saloon so, boo. |
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Post by Bilbo on Jun 23, 2022 18:15:55 GMT
So today I decided it was time to take a closer look at that small hole in the floor/sill area, and deal with any remaining rust underneath. I had previously undersealed a few of the clean areas, but hadn't bothered in the areas I thought might have some issues. I knew the hole I'd seen was going to be a little bit worse when I buzzed it back. Honestly it wasn't horrendous, and inside the sill was still solid, but I started out just peeling off the outer-most layer of decade old underseal. Bit grim:  Got a little bigger after I went at it with a wire wheel on the grinder:  Started buzzing back other areas. Here's the floorpan under the driver's feet area:  And from the inside:  Not ideal, but is what it is. I carried on with the wire wheel and found this grim chassis rail too (near the front):  And one tiny little spot on the passenger side floor:  Anyway, back to the original rust hole. I cut it back until I got to good metal on all sides:  I cleaned it up and filed it down a bit after this to get it nice and square. I had the rear wing panels I never used after we took the sills from them, so I am using them for cuts for this work. I made a patch up out of cardboard, then cut it out in steel. The welder took a little bit of messing about with to get a nice tack out of it, but got there in the end. Welded the fresh steel in, then buzzed the welds back. Took the kick plates off and looked through the holes as I went. Mainly to check for fire, as there is cavity wax in there and that likes to go up very easily. Luckily no fire, and as I went eventually no daylight could be seen, so it's welded up nicely all the way around.  Never done any bodywork or thin chassis work before, so I'm quite happy with the result. Let it cool down, seam sealed over the welds, and sprayed a decent amount of cavity wax inside to coat the inside of the repair. Once the seam sealer was set I went over the entire sill section I had buzzed back in underbody primer:  Then a decent coat of stone chip. Decided against that bitumen based stuff, Waxoyl and the like, I really hate it. It never seems to be dry and it's so messy. A decent stone chip protection and it was done:  1 hole down, 3 to go, will carry on tomorrow. But it feels good to be getting the old underseal off and really taking a good look at the underside, as there are so many areas that can rust, not just the outer sills and arches. Will have the main floorpan and underbody mint in the next week or so. |
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Post by Zed. on Jun 23, 2022 19:20:06 GMT
my Chevette Hs * is sorta in the garden below the remains of a tarpaulin awaiting attention, only had it ~20 years....... no photo's as it's embaressing Rich. * = remains & not realy origonal rallycar project I would say I'd have it off you, but it's not a saloon so, boo. just think what you'd be missing, something like  www.ebay.co.uk/itm/234578639868there was a wider tarmac version  Rich. |
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Post by Bilbo on Jun 24, 2022 22:14:26 GMT
I would say I'd have it off you, but it's not a saloon so, boo. just think what you'd be missing, something like www.ebay.co.uk/itm/234578639868there was a wider tarmac version Rich. They are very cool tbf, but I think a standard 5 engine would be a real anti-climax with a shell that looked like that haha. |
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Post by Bilbo on Jun 24, 2022 22:22:38 GMT
So, cracked on with the next rust hole today. Driver's footwell, this one: Gave it another buzz with the wire wheel, and it was a little wider spread than the initial hole, as it usually is. So I cut it back to clean metal:  It wasn't nice to weld up, very thin metal on the floor. I realised after starting I'd been using 0.8 wire the entire time, so changed the tip and wire to 0.6 and it did help a bit. Getting a good earth took a bit of doing, but it's done now. Welded up, seam sealed, primered, and undercoated.  Did the inside the same as well, probably a bit OTT, but I wanted both sides properly protected from day one:  Slowly getting there with the floorpan now, should have the other 2 holes welded up in the next week, and I'll then wire wheel back all the other underseal to check for anything else. Overall pretty happy with progress. |
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Post by Zed. on Jun 25, 2022 7:54:25 GMT
even the 'good' 5's are starting to suffer with tinworm, it'll be more next year but hopefully nothing major my '90 Eunos needs a rear panel (behind numberplate) & they aren't a known rot spot  Rich. |
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Post by Bilbo on Jul 4, 2022 11:55:54 GMT
even the 'good' 5's are starting to suffer with tinworm, it'll be more next year but hopefully nothing major  my '90 Eunos needs a rear panel (behind numberplate) & they aren't a known rot spot  Rich. Yeah I've not heard of them rusting there particularly often either. Should be a fairly simple one, at least you don't have to do any overhead welding, can't wait until I'm done with it haha. |
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Post by Zed. on Jul 4, 2022 22:05:25 GMT
even the 'good' 5's are starting to suffer with tinworm, it'll be more next year but hopefully nothing major my '90 Eunos needs a rear panel (behind numberplate) & they aren't a known rot spot Rich. Yeah I've not heard of them rusting there particularly often either. Should be a fairly simple one, at least you don't have to do any overhead welding, can't wait until I'm done with it haha. I sometimes weld better upside-down, think I concentrate more  Rich. |
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Post by Bilbo on Jul 27, 2022 16:31:57 GMT
Not been doing too much on the 5 lately, had a holiday and other stuff going on. Fixed a couple of loose screws in the front lip and changed the coolant, that's about it really. Took it to Beaulieu Simply Japanese on the weekend, was some cool stuff there. Got a few photos with my mate's 86, Team Cream and all that.   Stem seals are definitely getting sad now, my high RPM overrun and limiter gear changes are producing a fair puff of blue smoke, so I will keep an eye on that. To be honest 186k miles now, so it's hardly surprising, they've put in a hell of a shift. |
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LOL
le sigh