2/12/2023 0 Comments Rekord buddy manualHad a tidy up - this is an example of the carnage repairs on repairs. Will need a little skim before paint, but then so will the rest of the car. Got the tidying up to do, and finish up the sill end - hope to get to that this weekend. Once I was happy with the alignment & fit, I welded it fully:Īgain, I'm pretty happy with that tbh. Took a while to get it perfectly lined up - mantaphil provided a second pair of eyes when I started to go blind from looking. Next up the middle section was tied to the bottom rail, then the whole lot enclosed with a piece from the other car, trimmed to perfectly fit the hole: Made a bottom rail from a piece of old boiler, because it already had a nice neat 90deg bend in it, and repaired the inner, attaching it to the old inner, and the new bottom rail, all fully welded. I didn't think it would be salvageable, and the spare Rekord appears to have had a new sill in the not too distant, so I cut the whole section out (of both cars). The inner sill had a rusty hole, and the outer had a bad old repair actually on an even older repair. You can just about see it in the background here. I don't seem to have a photo of it done, will take one next time if I remember. The holes further to the left in that photo were then cleaned up & plated over with nice thick stuff. Where the long gash is along the side I tidied up / straightened the edges, then tapped them together & welded it up. It's going to be very very low in my ownership, so at least it's used to it already This car spent a past life running very low, and this rail seems to have taken a few knocks. Plug welded the mounting point (again cut from Elks scrap Monza) in the same way as the other side, but made a somewhat better job of it. I chose to do it like that (rather than cutting the repair exactly to the size of the hole) because it's where the seatbelt bolts through, so I wanted to make sure it was plenty strong. You can see the penetration from where I welded round on the inside too. This is for the rear outer seatbelt mount, which previously looked like this: The eagle-eyed amongst you will have noticed this hole in the background of one of the rear quarter pics: So, if you have a friend who is a welder/fabricator ( braeburn - 2 (unrelated) tags in one post!) ask him if he'd be kind enough to do this. I wanted to use the Frontera rail, because the injectors may or may not be bigger (they obviously inject enough for the 2.4 anyway) and the Manta ones have a zillion small lengths of pipe with jubilee clips, which ALWAYS leak. Pretty happy with that to be honest, took a lot longer to do than it did to write, and is probably the largest hole I've ever cut in a car then repairedĪ Frontera fuel rail doesn't fit a Manta inlet, cos the big end thing is hit by the throttle return spring. It's fully welded inside and out, along the bottem, and joined to the inner arch (I shaped the repair to the inner to precisely match the outer, then joined them together once the quarter was on) - it still needs tying in to the back panel, but that will end up all cut out first anyway. That's about it for the rear quarter I think. or the side trim (Elk hand! / paw? / hoof? Colonelk ) (HA! You can see our whiteboard (where the lists you keep seeing in this thread are written) in the background. I've cut out a bit more than I needed to to get back to clean metal, but all the big welds / joins are now hidden behind either the bumper. Here is (I hope) the method in my madness. You can see where I had to repair the repair panel in a couple of places. Missed some steps here - took ages finessing the repair panel to fit! Strange that from 2 massively rusty shells there are just about enough bits overall. Peeling off the back panel - this will all have to go at some point (last bit probably.) Inner boot floor & bottom section of the inner wing all looking pretty marvellous too. & got brave with the slitting disk *eeek* That's it for that side (see whiteboard list above) & so on to the O/S. (bonus points for having my buddy braeburn in the background welding up my Trabant )Ĭan't find an 'after' pic, but it's all straight & primered. Update time!įinished up tidying the passenger side first:
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