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5 GT Turbo R5 GT Turbo - Complete strip down and re-build #1

I went and picked up some spares at the weekend!!
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The wife was not impressed when I cam back with this lot! :)
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I told her that you never know when you might need a piece of scrap metal! I didn't have the heart to let the fella just weigh them in!
Anyway, back to the rust removal!
I got into the rear arms again. I took the advice from the forum and cut things back to reveal the extent of the rust, which wasn't as bad as I thought it would be!
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I got the wire brush on it to see how bad it really is!
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I then welded it in, once I was happy with the fit.
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As I was welding this piece in, I noticed a small hole that appeared, so I got the wire brush on the area and it just flaked apart! will this rust ever end?
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You can just see the hole inside of the cross member! gonna have to cut the member out to get to the rust! I got some tape and marked where I am going to cut! I got the heavier wire brush on the grinder and exposed more peppering!

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You can see where the rust converter has seeped through the pin holes in the metal!
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The member section is in pretty bad shape where it connects to the outrigger!
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I decided to have a go at repairing it! and made some patches!

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I then welded them together!
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I then made a replacement for the piece I cut off and gave it all a good going over with the wire brush! and then tried it on for one last fitting before spraying the inside with etch primer.
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I got the piece that I made and painted earlier for the sidewall section of the outrigger and got that welded in place.
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I then ground all the welds down, test fitted it and drilled the plug weld holes.
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I then gave the area a spray of etch primer!
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Then on to re-fitting the piece I cut out earlier!!
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Got it welded in and ground down, then dropped some etch primer on it for now!
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Thanks for your advice guys, I think it turned out ok! Just got to finish the other piece that I cut off and that should be this side finished! Luckily the other side looks ok!

Thanks for reading!
 
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Bugger me, you’re getting very proficient with that metal joiner sir!! 👍👍👍👍
Thanks @Big Steve - Raider I have had lots of practice!! ;) Just when I think I am ready to do something other than, cut, make, weld, more rust appears!!
It was around this time last year that I started on this journey and have learn't a lot along the way! Still a long way to go I know, but still enjoying it! It's good to have the support of the forum also, it keeps me motivated.
 
In my latest episode of beat the rust! I got very nervous after seeing @MOS and @Turbell posts, so I got a pick and had a little dig where the rear axle bolts on. I did think it looked ok, but once I started digging I saw a little hole so dug deeper and decided to cut the top piece off to have a more thorough look!
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Great!
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I gave it a whizzing with the wire brush!
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I then cut the rust out!!
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There was then only one piece of metal left on the top, so I cut that off too, just to check!
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More of the ginger stuff!! I gave it a clean with the grinder and then set about making a patch!
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I sprayed some rust inhibiting paint in here!
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New patch made!
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I then got on with welding the patch in place!!
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After grinding down there were a couple of spots that needed a blob of weld! But pretty happy with the result!
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I then ground it down and got some etch primer on the whole thing. Just need to make the cover patch now!!
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Thanks for reading guys!
 
Double skins mean trouble.
Preach John Stamos GIF by Fuller House
 
Back to the rust hunt, although you don't have to do much hunting!!! its f*****g everywhere!!
I carried on with the rear suspension area! I got some thicker metal for this!
First off though, the cardboard template!!
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I rubbed the cardboard to give me the hole locations, it worked a treat!
I then cut a metal version with the jigsaw!
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I then marked and drilled all of the holes, drain, bolt and plug weld!
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I then gave the rear of it a lick of etch primer!
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and then a lick of some black paint that I had knocking about.
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I also gave the car a lick of primer and paint, that should help hold the rust at bay!!
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Happy with the fit so i got it welded in and ground down!
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Had a bit of messing to do with this bit but got there in the end!
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I then had a look at the other side and just pryed the edge of the metal open to get a better look.......
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More ginger stuff!!!!
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I also remembered @MOS post with the exhaust bracket so had a look behind there also, just for good measure!IMG_0202.webp
Not too bad, looks like I have caught it in time, just a good clean up and some paint should do it for that!
I gave the area a whizz with the wire brush, the same ones that @DaveL485 shows on his post, the ones that that fire metal spears at your face at 100mph!! :) Really effective though!
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I drilled all of the spot welds out and cut and removed the outer skin!
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Again, this looked perfect from the outside!! This will be the first area I do on the next project ;)
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I gave it another whizz with the wire brush and contemplated just cutting out the patches for a second, but decided in true Turbo Renault style to cut the bloody lot out!!!
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I gave this a whizz with the wire brush also and got some etch primer in there!
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I also gave the area where the exhaust bracket sat the same treatment.
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I then gave the exhaust bracket a clean up and a coat of primer while I was waiting for the other paint to dry!
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I then set about cutting the new patches, I sued the pieces I cut out as templates this time!
Again I used the jigsaw to cut these out of the thicker metal!!
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Looks like I am making machete's!!
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I gave it a quick trial fit before getting some primer on the back of it.
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I also gave the car a lick of paint inside the member!
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I then gave the cover piece for this a lick of paint on the inside!
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Once this had dried I set about welding it in place.
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Once in and ground down, I got some etch primer on it! and then some paint!
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I then got the cover piece over and got that welded in place.
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I then got the exhaust bracket back on!
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and ground everything down! I then mad the tab and welded it back on!
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Looks quite original!!
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Real piece of mind that! I now know that the rear is solid!! Next front jacking points and finish some of the grinding inside the car!
Thanks for reading guys, and thanks for the heads up on these nasty spots!
 
You get a lot of work done in no time🙌 Looks great! That rotisserie is worth it’s weight in gold, isn’t it?
Ha ha, without the Rotisserie I would be a cripple!! With regards to the work, I try to get an hour a night in! Ive been off it this week with a piece of metal in my eye! getting better now though! new safety glasses bought! As much as I can't wait to be finished with the cutting and welding, I think I'll miss it when I'm on to the next stage! Thanks for your post, it has helped me no end!
 
On it again today! I feel like I live in the garage at the minute!! I started with a little thing that has been bugging me for a while. There is a rusted screw on the rear underside.
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I had a rummage through the scrap bits that I bought the other week, and by pure chance the exact section of floor was there!!


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So I gave it a clean up just to check its OK and proceeded to get the grinder out!
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I cut the existing one out and made a cardboard template
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I then got to work welding it in....
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Not the sexiest of welds, but they're all good and will be ground down!
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All good! Then on to the front jacking point. The ones I bought do not fit correctly, so this is going to be a chop n chase mission!
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Had a bit of a nightmare with this....
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Trimming it bit by bit until it is somewhere near! I then cut a piece of metal to form a new flap on the jacking point
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I then took it to the bench and trimmed and fully welded it, inside and out!

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I'll give it a final grind when it is fixed in place!
Once I was happy with the fit, I marked and drilled all the holes for the plug welds!
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I then got the beast of a wire brush on the underside of the car and cleared all of the paint and rust converter away
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I also gave the jacking point inner side a brush and a couple of coats of etch primer, then the same the underside of the car.
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Once the primer on the car had dried, I got some masking tape and taped off an area for some seam sealer to go in behind where the jacking point is going!
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My first attempt at seam sealing!
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While this was setting, I got some stone chip paint on the inside of the jacking point, I'm not going to be able to get afterwards!
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I then taped and sealed the other side where the jacking point will go.
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After the stone chip had dried, I got some waxoyl stuff and sprayed that on the inside of the jacking point...weird stuff that is!
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I then sprayed the underside of the car with stone chip paint also.
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Then some of the waxoyl stuff!
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I then clamped the jacking point in place and got a small wire brush on the drill and cleaned the holes for the plug welds!
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I then gave it all some hammer to make sure that it is sitting down fully before welding in place!
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Not bad at all!!
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Thanks for reading guys!
 
Creeping forward mate, good work. You got to root it all out or it'll just come back again!
Its getting there now Dave, just the other jacking point to get on and a bit of grinding down inside the car and then I'm ready to wire brush the underside down and get the first coat of epoxy mastic on it! I don't think there are any areas of the metalwork left untouched now!
 
:) Its a gloves, glasses, full face mask and sleeves job! plus the squint awaiting the inevitable spear somewhere! really good at stripping the rust and shite away though!
I've had them stuck in my legs, arms, hands, i've had a few whacks in the face and one on the lip that really hurt! Just can't get anything else thats as effective though, they're really good for derusting without damaging or removing metal thickness like a flap disc.
 
@DaveL485 Got one in the chin yesterday, I couldn't pull it out as it had gone in too far. The wife took great pleasure in pulling it out with some tweezers!

I have been working on getting the welding closed out! I first had to cut and fix the other front jacking point, same process as before!
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More spears off the wire brush!
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Got that finished and then started to wire brush the underside of the car back to bare metal ready for the epoxy mastic coating!
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The brutal wire brush also revealed some further rust patches which I couldn't see before! so I got the welder out and made them good.
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Then carried on with the wire brush!!
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I then started masking off the rest of the car!
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I then noticed that I have bought the wrong coloured Mastic, so ordered replacement. I hope the flash rust doesn't get too bad, I can't face wire brushing it all again!!!

Thanksf or reading
 
Tough work isnt it, I suppose made a bit easier by the fact it was already dipped. I had to get through the underseal, seam sealer and rust as well, got some great black bogeys afterwards LOL 😂
 
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