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sleag40

Vauxhall Cavalier

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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.

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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.

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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.

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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 
 

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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. :( )

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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.

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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.

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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! 

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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.

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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.

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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.

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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

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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 

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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.

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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.

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

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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. 🙂

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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 
 

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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.

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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. 
 

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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)

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Welding it in. (This is the rear portion)

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And finally the completed inner arch lip.

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

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

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Let the tacking commence 

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Welds dressed back and pinholes attended to.

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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.  🙂
 

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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.

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Didn't think I was gonna get back on this until the weekend, but managed to snaffle a couple of hours on it this evening. Rear valance fettled up, zinc primed on the back, and tacked on. Also plug welded the valance to the lower rear quarters. 

773caeae41ab.jpg

I'll get it fully welded next time, hunger got the better of me this evening. 🙂

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Valance now welded, tidied up and zinc primed.

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With that done, the driver's side rear door came off so I could sort out the gap between the arch repair panel and the new outer sill.

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I'm gonna finish off the welding on the front part of the wheel arch + top of the sill next, then hopefully get the spit assembled on Monday.

I think I may have overestimated the amount of welding gas required - I've used about 15% of it so far!

e5187104fdf0.jpg 
 

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Offside sill now finished off

 

542f3dc74425.jpg 

The spit is now assembled, hopefully I'll get some bracketry made up and get it all attached this afternoon.  🙂

6b8fe3c290ad.jpg

Edited by sleag40

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Bracketry now completed - used a bit of box section at the front in the bumper bracket holes.

4de96c56691b.jpg 

Doubled up some 2mm plate for the rear - again using the bumper mount holes.

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Everything was then aligned and tightened before starting to wind it up. Seen here with the axle stands removed, and a bit of a tilt on.

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Next time, I'll wind it up enough to roll it right on its side - hunger ended the session again. 

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I've only wound it up a few inches so far - I may need to drop it back onto the axle stands so I can go up a notch on the pivot points. Even so, it made plug welding the bottom of the rear valance easier.

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Next on the to do list is to make up a jig to ensure that the spring plates go on in the correct place once the chassis rails have been repaired.

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After that comes the utter joy of cleaning all the sealant, paint and rust off the underside so it can be repaired/repainted + resealed. 😞

 

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Not much time on this recently, but I came up with this from a few bits of scrap.

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It bolts in tightly to the rear beam mounting point, and accurately indicates where the centre of the spring plate should be.

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As an added bonus, when the bend is redone the other way, it works for the other side too. 🙂

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Stole a bit of shed time this afternoon - the nearside spring plate now resides in the pile of jettisoned junk by the door. 

f4fddf2e59bc.jpg 

Once all the rotten metal was cut out, a piece was fashioned to repair the inner section of the leg.

aff9e3e6fbab.jpg 

And that's as far as I got today. 😞 New spring plates should be here by next weekend, so theres plenty of time to ensure there is some decent metal to weld them to. 🙂

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Been fishing + done a bit of gardening instead of toiling away in the shed this week. The arrival of these

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convinced me that it was time to get back on it. The piece made at the weekend was tacked in

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Then fully welded, and zinc primed.

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Got half way through making the outer chassis leg piece before I had to vacate. I'm making this out of 2mm sheet, and its obviously a lot more difficult to form into shape 

ebe8fc310702.jpg 

but should have it ready to mount the new spring plate at the weekend.  :)

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Not really my day today - first up, my big "working under cars" lighting rig has stopped working. Not the worst thing that could have occurred, but still a PITA (It's been on its last legs for a couple of weeks now). The outer chassis leg repair piece was finished, then welded in.

9d89b4892211.jpg 

I was just about to reach for one of the new spring plates, when I noticed that further up the chassis leg, near where it is spot welded to the floor, the metal looked a little dodgy. After hitting it with the knotted wire wheel, a couple of tiny holes appeared about an inch below the joint with the floor. I had to cut it out, and it was pretty awkward to do that due to its position being partially obscured by the inboard wheel tub. 

No big light means no decent pictures, (I'll hopefully get it sorted tomorrow) but the rest of the day was spent cutting out the poxy section of chassis leg, then making up this piece to replace that which has been removed.

13d2a5e5a83b.jpg 

Hopefully I'll get that welded in tomorrow, then the spring plate can go on - completing this side of the car.   🙂
 

Edited by sleag40

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Chassis leg repair piece now in, and then zinc primed.

728884dc54a6.jpg 

Spring plate drilled for plug welding, bare metalled, then zinc primed.

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Boshed on with the positioning jig.

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Started to cut out the poxy bits on the driver's side - it's a bit worse than the passenger side was - I'll need to cut this back a bit further!

a356134a8b08.jpg 
 

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Not had a lot of time for this recently, but have managed to get a bit done this week. The chassis leg pox was cut out, and a piece was knocked up and stuck in to replace the inner section.

a3ec6ec24d6b.jpg

A template was made for the outer section, then copied into 2mm sheet and trimmed to fit nicely into the gap that requires filling.

0434d6db8c4b.jpg 

The outer piece is ready to weld in now, and should be going in on Saturday (closely followed by the spring plate!)  🙂

Edited by sleag40

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Finished early today, so got stuck in! Outer chassis leg became complete again.

a7eac03f99e3.jpg

Spring plate added using the piece of scrap fashioned into a makeshift jig.

9f48d3885a09.jpg 

Measuring from the centre of the spring plate to the inboard hole of the rear beam mounting points on both sides revealed that one side is within a millimetre of the other. Similar results were measured when the outboard holes were used - I'm chalking that up as a win! 🙂

Next up, attention was turned to removing the tailgate. Locking stuff was removed, as was the wiper mech + washer jet. The washer hose was withdrawn from the tailgate, followed by the wiring on the other side.

8e7904e418c8.jpg 

Just need to remove the struts and hinge pin clips and it can come off. (a second pair of hands will then be required)

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I managed to find someone to help me lift off the tail gate - theres usually plenty of people around, but not when you need there to be.!

2949d4f3527e.jpg 

I can't keep putting off cleaning back the underside to the metal - I let myself in gently by finishing off the cleaning of the nearside rear tub.

8959de16f6f6.jpg

Grim times ahead. 😞

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