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

I have a jc5 to rebuild soon, how difficult is it to split the box/gearset?

Id put the outer cvs in if rolling the shell in and out of the garage or the front wheelbearings might fall to bits.
Hi @Brigsy, splitting the box isn't an issue, it took me a couple of hours, but I have never split a gearbox before. I started by getting the gears locked and stripped 5th and reverse first. I can send you the JB3 manual and a copy of the haynes pages if you like!
 
I got out there today and continued with the filling and sanding, I also noticed that the seam seal was missing from the roof gutters so I got the passenger side masked up and the seam seal applied.
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I ran down the gutter with a wire brush before squirting the seam seal.
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I then got on with the filling and sanding
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I found dents and dips in the panels that I didn't know were there!!
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I'll give it a wipe down tomorrow and get a coat of epoxy over the top as I have hit bare metal in some places.
Thanks for reading guys!
 
Got out there again today, god its cold!!!
I got the car masked up first and then got the tailgate off and on to a stand.
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I then gave the car, tailgate and drivers door a quick blast with some 320G and then a wipe down with some panel wipe.IMG_6173.JPG
I got geared up and mixed some epoxy!
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I then got on with spaying the epoxy on!
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I got some epoxy inside the door, I am going to try the cavity sealer gun to get epoxy all inside the door.
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One side done!
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Any further imperfections now will be picked up with the high build primer!
I then got the plastics out and gave them a good clean with good old fashioned soap and water and a bit of elbow grease!

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There was quite a bit of underseal and crap stuck to these so it took a while!
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They came up ok!
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All clean! Just the bumpers and side skirts to do now!
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The epoxy dried ok too!
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Thanks for reading guys!
 
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I got out there on Saturday and carried on with the filling and sanding in a bid to get the 5's shape back and ready for HB primer!IMG_6192.webp
This was one of the first areas I welded so the welds were quite rough and there was quite a lot of distortion to hide! I also filled the holes in the tailgate for the number plate.
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I also tapped the small dents in the roof out and got some filler in them!
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I also put the poster up that my son got me for xmas!
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On another note, After much deliberation, I have decided to paint it myself. I have consulted a couple of paint suppliers and have settled on one and bought all the gear! Renault 608 Tungsten Met.
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Just got to get the filling, sanding and epoxy all finished before I start on the HB primer, base coat and clear coat! Looks like I am about to learn another skill! Shame its not like the matrix!
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Oh well hours of University of Youtube is coming up!
Have also got some more of the plastics out for clean - Bumpers and side skirts. One of the side skirts has been filled with expanding foam and there are lots of cracks and clip tabs broken off!!
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I am thinking that I can use some fibre glass to repair these side skirts, any ideas as I really don't want to pay £250 for an equally knackered set of skirts!

Thanks for reading guys!
 
On it again today, I started by masking the roof gutter ready for the seam seal, and then carried on with the filler to the drivers side and then guide coated it!IMG_6217.webp
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I left the car outside the week before last while I cleaned up and it pissed down with rain on it. Bit of a blessing really as I noticed some orange streaking from the tailgate hydraulic arm connection points, so today I gave the area a wire brush and then masked them off for some brush on seam seal.
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I also got some more filler on the rear side window as it still felt a little 'lumpy' and then sanding it down smooth.
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I then got the seam seal on the gutter and around both tailgate connection points!
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I then finished seam sealing/ bonding the spare bonnet that I have, I am going to use this one, the one I repaired isn't good enough! This needs some repairs to the front edge!
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I then started filling the doors....
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and sanded the car down and applied more filler!
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Once this door was sanded, I got on to the other door, I filled in the area where I had welded and then found other dinks and dents and filled them!
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In between filling and waiting for it to set, I began sanding down the front and rear arches from the body kit!
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I keep finding these little hidden renault signs in the strangest of places!
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I then got in the loft and got the final piece of plastic down!
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I stripped the badges off and removed the lock ready for cleaning, sanding, and painting!
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Not really enjoying the bodywork side of things! filling, sanding, filling, sanding!! All day again and it feels like very little progress has been made!

Thanks for reading guys!
 
Your right on the filling and sanding , it’s a pain but needs must , I’m not great at it ,
Try and get one panel done at a time and then move on to the next , it makes me feel I’m making progress rather than 10 patches of filler to flatten . Good quality gear makes the job so much easier.
Hats off to you , big project coming together nicely.
 
Your right on the filling and sanding , it’s a pain but needs must , I’m not great at it ,
Try and get one panel done at a time and then move on to the next , it makes me feel I’m making progress rather than 10 patches of filler to flatten . Good quality gear makes the job so much easier.
Hats off to you , big project coming together nicely.
Thanks Stu, I'm using Upol filler, It doesn't go on like I see in the you tube videos where they skim coat the entire panel, theirs seems a lot more liquid.
 
Got out there today, I had to have a clean up first, I was beginning to drown in the mess!
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I then got the passenger door out and began to mask it up ready for seam seal!
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I gave the little patches of surface rust a going over with a small wire brush first
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Then on with the seam sealer!
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Once this was all on, I dabbed it down with a wet finger and smoothed it off. I then left it for 10-15 mins just to let it stiffen up a bit. I then got to work pulling the tape off, with my trusty box next to me for the waste tape!
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I then mixed up some epoxy to try in the wax gun to see if I could get it inside the doors,
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This didn't work too well so I binned it off and poured the paint into the gun and gave the doors a blast!
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Actually quite happy with the filling work, Its not perfect, but I'm hoping the high build primer will take care of the rest with minimal further filling required. Had to stop out there for a while but then went back in a couple of hours later and began to mask the car up again!
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I used an old cardboard box to mask off the underside of the car, a lot less hassle than trying to stick paper up there, and It doesn't tear when I kick it by accident! :)
I mixed up some more epoxy and gave the front and rear plastic arches a wipe with panel prep!
I then got on with spraying the epoxy.
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It went on really well again, it does seem very forgiving!
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I also got some paint on the seam seal around the hatch connectors!
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I then gave the plastic bits a coat of epoxy!
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The plan is to get everything into epoxy primer before moving on to the High-build primer.

Thanks for reading guys!
 
I got out there today with a mission to get the bonnet welded up and primed on the inside, I also wanted to sand down the wing filler, and get it back into epoxy! When I first looked at this bonnet I thought it was all good until I gave it a blast with the wire brush and a load of pinholes began to appear along the inner skin. I treated this with the FE123 rust converter a couple of days back so should be all good now!IMG_6275.webp
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I decided that it would be too much to cut this out and weld in new plates, so I decide to blast it with the welder and blow it out until I hit good metal! It worked quite well tbh!
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This one was a right pain in the backside! It just kept on blowing, I ended up blowing out most of the right hand side of the metal, but eventually got to good metal in the end!
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Once I had done this, I got the seam seal out again! and finished off the bits that I had missed previously! I also got a skim of filler over the welds!

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I then moved on to the wing and got that sanded back! IMG_6283.webp
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I hit the rest of the wing with some 150grit.
Whilst I had the filler out, I skimmed over the welds on the rear of the car, I have been meaning to do this for a long time!
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I got them sanded back and gave it all a good clean with panel prep and then a tack rag!
I also put a skim over the side of the car again as there were some pinholes in the filler, and I wasn't entirely happy with the filler into the door where I have welded the replacement cill, It looks much better now!
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I then mixed up some epoxy primer and gave all the panels a wipe and tack off! On with the paint!
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I was messing about with the settings on the gun and managed to get it spraying nice but not using too much paint! I ended up with paint to spare so I got the plastics out and hit them with some 60grit, wipe and tack! Then paint!
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Whilst rushing to get the plastics out of the garage to sand down, I tripped and dropped one of the rear plastics from above the rear light! of course it landed on the weakest part and snapped the end off it!
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You *#%@!&*(+................................. Luckily, I have been hoarding various parts from various sources and now have a renault 5 full of renault 5 parts, including quite a few sets of plastics!
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After 5 mins or so, I emerged with a replacement for the broken one. I gave it a clean, sanded it down and got some epoxy on it!
Only the bumpers left to clean, sand and epoxy now, then on to high build primer! :)
I think I'm going to hit the engine bay and inside of the car with some 180grit and then give the Tungsten paint a go!
Looking back through some older pictures, I noticed that the boot area has what looks like sound proofing on it. Does anyone know where I can get this from?
Thanks for reading guys!
 
Sterling work there @Chris74# !!

Not sure if you’re uploading the photos in their original size, but they seem to take an age to load of my phone?? Maybe try uploading them smaller?
Thanks @bigsteveraider
Sterling work there @Chris74# !!

Not sure if you’re uploading the photos in their original size, but they seem to take an age to load of my phone?? Maybe try uploading them smaller?
Been having some difficulty recently with getting updates on! I haven't changed my camera or the settings on it, everything seems really slow!
 
Got out there today hoping to get the bonnet finished and the bumpers, skirts, tailgate plastic and grille cleaned, sanded and in epoxy! Unfortunately, the bumpers and skirts were a lot dirtier that I thought, and had old bituminous undersea caked on - thirty years worth! I'd already got rust convertor and epoxy along the front edge of the bonnet.
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I mixed up some filler and spread it on there!
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I then went and got the grille out of the shed, It has some damage so will have to work out a way to repair it! I removed the edge first and put it to one side.
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The bottom fin on the grill has broken away and the two outer tabs on the top are also broken off!
I promised the wife that I would wash her car so I went and did that while the filler set! I also thought that while the jet wash is out, I can give all the plastic bits a quick blast!
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There is all kinds of crap stuck to these! Whilst cleaning i noticed a crack in the rear bumper with a really bad attempt at a repair! More work!
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I ended up getting the little wire brush and some thinners to try an cut through the grime and underseal
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I know some people will say I am wasting my time cleaning the inside of the bumpers, and maybe I am, but they look great clean!! ;)
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I found lots of cracks and chunks missing out of the skirts, these are really caked in undersea, what a nightmare!
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Lots of thinner and wire brush going on, but it is working, just taking an age!
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Ran out of light so called it a day! I'll have to finish the skirts another time! The bumpers look clean though! 1 step closer!
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Thanks for reading guys!
 
I got the spare gearbox cover back from the vapour blaster, checked the shaft seal and it is a tight fit! I am amazed just how much the caustic ate off the aluminium cast!
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I also got some sound deadening mats for underneath the front seats! I almost forgot, but while reading @Big Steve - Raider post, it reminded me that I need to fit the sound deadening prior to paint! Thanks Steve!
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I decided to give the inside of the wings a good couple of coats of stonechip
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I filled the holes in the bumper that someone had drilled and sanded them smooth!!IMG_6343.JPG
and then sanded the whole bumper down ready for epoxy
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I then got on to the rear bumper and carefully removed the rubbing strips after reading @clarky_gtt post and the game he had with his!
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Found some damage and sanded it down as much as possible, will have to repair it properly once everything else is sanded down!
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Done! Then stone chipped the inside of the other wing!
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I then moved on to the final bits! This is really testing my patience!
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I gave this a wipe with some thinners to get the grime off, and then gave it a rub down!
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Then on to the grille! same drill, rub, rub, rub!
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Then on to the side skirts! These are battered!
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Then on to the other one!
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Then I got the fibreglass out, first time ever using this stuff!! Not impressed!
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I then got on with sanding the final bits down!
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Its getting busy in here! Need a dry day so I can put the car outside and paint the plastic bits!IMG_6393.JPG
I got some epoxy glue on the grille to see if it holds!
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If it holds, I'll sand it back before painting it!
Thats it for this update. Really not enjoying this stage, but will soon be past it!
Thanks for reading guys!
 
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