5 GT Turbo 11 years later silver bullet comes home

[Brigsy]

Chassis rail crack is interesting. Looks like shock has bottomed out in the past combined with abit of corrosion causing it

 

[Duncan Grier]

@Brigsy definitely going to be having a proper closer look and make sure A1 after and suspect you could be correct...other side no signs of the same

 

[DaveL485]

God it feels like it never ends doesnt it. This is giving me flashbacks/the thousand yard stare

 

[Duncan Grier]

You are not wrong @DaveL485 lol

Definetly a keep in mind the end goal, park it and pick a task, focus on said task, stay on task, complete task before moving to the next....never move more than 1 job ahead is my advice

While challenging with limited short bursts of time available the above approach is working

 

[Duncan Grier]

90 mins of picking apart bits to get some mooooooore focused tasks

 

[Big Steve - Raider]

Wow… the tin worm sure had a chomp of that car..!

 

[DaveL485]

Urgh, look at the state of that. If values hadn't shot back up the way they have it'd be in the crusher!

 

[Duncan Grier]

More really exciting pictures of my progress since last time ......might give you all a break for a few weeks/month of my power hrs

 

[Turbell]

Keep it coming, I'm enjoying seeing progress !
Few ARC geezers on Autoraise rally were singing the praises for Upol Raptor bedliner coating for underside , one bloke was mixing colour to it.
Look it up, applied by regular shutz type gun.
Very tough, thin it out and use it on suspension bits.
Not tried it myself yet, but if I ever do another shitbox I might give it a whirl.

 

[Duncan Grier]

Thanks @Turbell will have a look and as you asked some updated pics below

Was not 100% happy so ran some more weld in and ground back, it was solid just.....well just me lol



Then cut out section of inner arch that sits in rear of sill and cleaned up.

Made new section to weld on (never got finished pic before welding on but just had holes enlarged for plug weld and shaped drainage section etc)



Some more primer zinc and weld through and another section solid.....did forget to drill 1 hole in plate but no drama to sort

 

[Duncan Grier]

Not much time in garage but couple hrs just squeezed in.

Wasted a bit of time cutting last bit of inner sill needed only to then see the bit I had already done last time plasma cutter was out doh

Anyway inner sill in, will go over any pins holes usual process, final flap wheel and can get hydro80 and primmed

In my push to get section done forgot to clean back to metal the contact areas for spot welder so it does not fuse great, no real drama as only 4 to do at the rear and will plug weld

Was nice to look back as leaving and see fresh metal in and while steady seeing the progress

 

[Turbell]

Tank strong.

 

[DaveL485]

Why grind back all that weld thats going to live inside the sill? You only need the bottom bit flat to join the outer sill to the inner - save yourself a bit of effort...

 

[Duncan Grier]

Agree @DaveL485

Meant flap wheel over any new welds from final sign off and just a quick once over not dressing anymore than in picture

But also cant stop myself and over the amount of welding the car is getting will save at least 0.3kg lol

 

[Duncan Grier]

Couple hours of fun straight after work. Finished inner touch up and cut and filled last section and small section over top to match original.

Started rear jacking point and ran out of gas

So measured up and cut outer sill to perk me up

My logic is finish rear jacking point, arch insert and few minor items before moving onto cutting out front section of rot....1 section at a time. Plan if I get gas in good time to have the sill on this week

 

[DaveL485]

Last time I went to weld I was out of gas too, I watch the level cos running out really pisses me off and i'd had about 1000psi left (1/3rd), but divvy here forgot to close the valves off after use and it has all leaked away over a 2 week period. I was fuming!

 

[Duncan Grier]

Yep done similar on previous fill, choice words were deployed....especially with the cost of it going up, find myself turning gas bottle off between blasts of welding as paranoid its all going out for free lol

Think I am going to look at 200L bottle 250bar bad boy today or certainly bigger than I have now as its all adding up

 

[Steve Swan]

Urgh, look at the state of that. If values hadn't shot back up the way they have it'd be in the crusher!

How many supposedly good cars are like this when picked apart?? in my personal experience everything I picked apart was a lot worse than it looked, possibly with the exception of @paule78 's R8 which was much better than it looked and only got a little worse on stripping.
This explains my cynical approach to many things in life .............

 

[Steve Swan]

Keep it coming, I'm enjoying seeing progress !
Few ARC geezers on Autoraise rally were singing the praises for Upol Raptor bedliner coating for underside , one bloke was mixing colour to it.
Look it up, applied by regular shutz type gun.
Very tough, thin it out and use it on suspension bits.
Not tried it myself yet, but if I ever do another shitbox I might give it a whirl.

We used Raptor on Paul's 8 I was impressed by it, hope to use on the Dauph if we can colour ok.

 

[Steve Swan]

@Duncan Grier. You have got it on the run now. Too late as usual, but as I'm getting the Dauph Ready for the Bodyshop, I am tiding up the repair areas to save time. I borrowed their Panel flangeing tool. What a revelation !! I have a Handraulic version like a modified set of Vicegrips which puts an offset on the panel edge for seamless overlaps. This is heart achingly slow. The little Air operated one I borrowed flanged the edge in minutes giving a perfectly flat join. This would have worked along the top of your old sill allowing you to bring the replacement up with about 15mm overlap. It also incorporated a 5mm punch to make holes in one panel for Mig plug welding. Forming the swage also makes it less likely to distort. I will try to find a link
Link Clarke Cat62 Air Punch And Flange Tool