Jump to content
sleag40

Vauxhall Cavalier

Recommended Posts

sleag40

Nearside sill now finished off.

56cf3b332080.jpg 

I decided to have a look at the offside rear wheel tub - this was how it looked to begin with.

c349f4f09695.jpg 

Once it had seen some wire wheel action, and a couple of bits of metal that were held in with filler had been ousted, I could see the extent of the job in hand.

089637e94d2e.jpg 

It's not very clear just how much metal is missing in the above pic - I'll try and get a better one at some point! The inboard side of the tub is pretty good - just one small repair is required right in the middle of the bottom edge.

3aec982b8d7c.jpg 

Due to a complete lack of arch lip reference points on this side, I made a start by getting the front part of the outer arch trimmed and positioned so I have something to work to when rebuilding the inner arch/tub.

fdfcdce16b94.jpg 
 

Share this post


Link to post
Share on other sites
sleag40

Got a little bit further along with the mess that is the offside rear wheel tub. Only had time to make and weld in the piece that replaces the rotten front part of the tub. 

994b25bc5828.jpg

Once I've finished cleaning back the welds, the plan is to replace the inner arch lip as far around as I have the time for over the weekend. (My rollover spit was supposed to arrive today, but it'll be next week now. :( )

Share this post


Link to post
Share on other sites
sleag40

Front part of the inner arch lip now in position - was difficult to get it somewhere near the right place on this side due to the lack of any remains of the original one.

eb5c382ac354.jpg

The front part of the outer arch then went on - seen here after half grinding the welds back so that I can see where any little gaps are that need hitting with the sparkly stick.

c0c0f28138a7.jpg

Finished the session by making a start fettling the rear part of the outer arch to get a good fit. (This one is a worse pressing than the nearside one was.  )

6dcd19a01a52.jpg

Hopefully more tomorrow! 

Share this post


Link to post
Share on other sites
sleag40

Lots of time spent on this today, but not a right lot achieved. Replaced a section of wheel tub + inner arch lip. It took a while, but so far a perfect fit with the outer arch.

d3bb3981b3cf.jpg 

Next up a load of rusty bits were cut out of the back of the wheel tub, inner rear quarter bottom and outer rear quarter bottom.. The viable metal left behind was kind of flapping in the breeze, so a multitude of small and fiddly repairs were done to the wheel tub/inner rear quarter to tie it all together, and give me something to weld to when it comes to replacing the outboard section of the back of the wheel tub. (Phew!)

ed0573d60bf1.jpg 

Zinc rich primer then splashed around before teatime.

Share this post


Link to post
Share on other sites
sleag40

From Monday 6th

After a bit of time weighing up the job this morning, I came to the conclusion that the fuel filler part of the rear quarter would need repairing before anything else could be done. Started the session looking like this.

2c3392e80110.jpg 

The rusty metal of the outboard side of the tub above the fuel filler was then cut right back before cracking on with the fuel filler aperture itself. A couple of hours later, I was pleased to be looking at this.

d72fdebd9fb1.jpg 

I'll clean up and paint both sides of the fuel filler, then I can get on with replacing the rear outboard wheel tub + inner arch lip.

408eaf65426a.jpg 

Once this arch/tub is completed, the plan is to weld the outer rear valance on before it goes up on the spit.

Feels like I'm getting through it now. 🙂
 

Edited by sleag40

Share this post


Link to post
Share on other sites
sleag40

Not been much time available the last couple of days just enough to clean back to metal both sides of the fuel filler hole, treat with Hydrate 80, then zinc prime it.

f0ac7634d684.jpg 

I'm just weighing up wether to rebuild the missing structure on the car, or make it off the car then weld in when completed - both options have their pros and cons.

When I left the unit today leaving the outer panel clamped on, it struck me that although not completed by any stretch of the imagination, that this is the most complete this wheel arch has looked for a fair while.

a2428408d1c6.jpg 

Share this post


Link to post
Share on other sites
sleag40

Got a few hours on this over the last couple of days - progress is progress! The rearmost part of the top of the tub was cobbled together off the car, seen here part way through fabrication.

844e88e34b4c.jpg

This was then welded into position (awkward!), allowing a second piece to be persuaded into a shape that fits the gap that remains, whilst leaving something in the right sort of area to attach the inner arch lip to.

008253bcac92.jpg

Once whittled down with a flap disc to fit, this was welded in.

6bfb067dd63e.jpg

Once I've finished cleaning back the welds, I'm good to complete the bottom of the back of the wheel tub + get the inner arch lip on there - the most difficult part of this corner is done now. 🙂

Share this post


Link to post
Share on other sites
sleag40

My arthritis got the better of me today, but still got a little bit done. Went round all the recent welds with a LED torch, and any pinholes were addressed with the sparkly stick. Once that was done, I replaced the bottom of the inner rear quarter - the corner piece to finish the gap left between this and the inner rear valance is under construction and will be stuck in next time.

cb4203f4bd8e.jpg 
 

Share this post


Link to post
Share on other sites
sleag40

The weather has been too good of late to spend in a dusty lock up, so I've given it a miss the last couple of days. I gave it a cheeky hour or so on the way home from work today and got a couple more small jobs done.

The missing offside inner rear corner I made at the weekend went on first.

1580d998f924.jpg

Then the lower part of the outboard section of the wheel tub was fashioned and welded in before I went home.

22e62e62edc4.jpg

Next on the list is to get the rear half of the inner arch lip on there - probably be at the weekend now. 
 

Share this post


Link to post
Share on other sites
sleag40

Not had any spare time until today, and sadly only a couple of hours were available. (Was hoping to be on it all day!)

A bit of metal wrangling to replace the missing inner arch lip took place. (The marker pen shading + lines help me remove metal in the right places)

da1f395aef6b.jpg

Welding it in. (This is the rear portion)

bc832dc59527.jpg

And finally the completed inner arch lip.

8702887c6280.jpg

I'm hoping to get the outer on tomorrow.(unless foiled by other stuff like today)

Share this post


Link to post
Share on other sites
sleag40

I didn't get down to the shed until midday, but got straight on with trimming  + fettling.

dfe7c09de6ef.jpg

Let the tacking commence 

f48319f8bd5f.jpg

Welds dressed back and pinholes attended to.

5d5e7c882ee3.jpg

The rear quarter panel was a little distorted from when the bodge repairs were done, but its ended up pretty reasonable. It does require a little fettling with a hammer and dolly in two small spots though.

4d2d7ba7bd1d.jpg

Hopefully I can get that lower rear valance and rear quarter bottom on this week, then I can finally try out my rollover spit.  🙂
 

Share this post


Link to post
Share on other sites
sleag40

Stopped off at the shed on the way home today, and got the lower rear quarter bottom on.

3f1d00ca96d7.jpg

Just needs to be checked for pin holes, then I can get the lower rear valance fettled up and on.

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

  • Recently Browsing   0 members

    No registered users viewing this page.

×
×
  • Create New...

Important Information

We have placed cookies on your device to help make this website better. You can adjust your cookie settings, otherwise we'll assume you're okay to continue. Terms of Use Privacy Policy Guidelines