84 Beige Nova (Project parchment) Op rust must die

[bstardchild]

Impressive stuff - didn't know about the tie bar weak points - you certainly aren't going to pull those out

Looking forward to see what direction it all goes

[peester]

didnt know you was still going with this james, as well as the kadett. Nice one.

[wheeler]

Hello, the job you're doing looks great.

I'm interested in how you beat the contour into this part though:



I know about metal stretching but I can't see where exactly you stretched it.

[countvauxalot]

Thanks Chaps - wheeler i simply bent it by hand

[countvauxalot]

update

I began by tacking the tie bar mounts on to the new cross member so i could remove the support bars i had previously added, giving me more space and better access in the engine bay..







Then i made up some more small plates



And tacked them in





Welded them up





Letting them cool i got on with some more rough sanding of the plated areas







Fed up of grinding welds back for the minute i moved on to seam welding

Gave the area a quick clean off



Tapped the seams together with a hammer to make it easier to weld

From this



To this



Splatted some weld on - even though i though i had cleaned all the curse word out of the seams the welder still wasn't 100% happy as it was spitting and the welds aren't as good as i would have liked.







Then gave this side a quick clean off



And marked out the area of metal to be removed from the chassis leg for the alternator clearance.

Note seams tapped flat too





Happy with the position i made more of a permanent sketch so i could start chopping - ive included lots of pics at different angles for reference in case people need it.







Cut it out - all with the grinder









Made some measurements and made a template

[monkeytennis]

Hello matey, I Pm'd you back, if you could reply that would be great, it also takes my mind off your awesome fabricating skills

[countvauxalot]

PM on its way...

[countvauxalot]

New engine aquired



1800 16v small block x18xe1 (so mounts the same as the original engine and uses the same gearbox, shafts hubs etc)

I'm thinking R1 bike carbs

[spartacus]

Top work...any oppurtunity to say 'penetration' repeatedly has got to be good!

[countvauxalot]

Cheers chap

[vaghag]

just read this thread, great work mate!!

[dtvracing]

Car is coming along great, dotn worry about the welds on the seams, paint covers all sins. seam sealer is C%#T when trying to weld neatly. but great job so far, looking forwward to the outcome of this

[countvauxalot]

Thanks guys

[countvauxalot]

All fits ok







Happy with the template i marked out the metal



cut it out with the grinder



And began to shape it to fit - note the curved radius's on the folded edges instead of the sharp 90 degree fold as the curve is easier on the eye.





Used the vice grips to start bending the curved area



Getting there with the bend



Then gave it a beating to help it along

[countvauxalot]

Getting there



This is nearly the completed shape just in need of some welding and cleaning up











I tried it in the hole for fit



Like a glove! happy with that.







Happy with the fit i welded it up

[countvauxalot]

And cleaned it off a little with the grinder first then the DA sander and a die grinder for the hard to reach areas.













Moving on i tacked it in place







Then welded it in







And began to clean it off

[countvauxalot]

A little more tidying





Getting there now





And a final sand



I'm happy with that





Pleased with the result i decided to call it a day and shot some primer on it to keep it from flash rusting until next time











And on the other seam too



Thanks for looking

James

[nofrills]

Gotta say buddy this is just awsome and your fab skills are excellent.... loving the way this is coming along

[countvauxalot]

Mar 19, 2012 12:23:06 GMT nofrills said:

Gotta say buddy this is just awsome and your fab skills are excellent.... loving the way this is coming along

Thanks you sir - more updates soon ;D

[countvauxalot]

Hi good people!

I have for you an actual update!! this brings us up to last weekend.

So here she is looking very sorry for herself not having been touched for some time - shame on me i know.



However all of my previous work looks ok still





To get the ball rolling i stripped the front struts off the hub carriers





the end result ready for some cleaning





that sorted i moved back to the car, jacking it up a bit to have a poke around



remember this!! Its the main reason i was going to go with the saloon arches as it really needs a quarter given the amount of rust and damage to the arch (the damage goes up past the area a normal repair panel would cover)



and this



having never investigated this cr@p properly i decided attack it with the grinder, now i kew the filler was thick but ffs!



once it was ground back you can see the arch has been beaten back all the way to the crease of the arch 3ugger!





The whole area was like a winter wonderland!



Looking to investigate further i decided to remove the sill - spot welds uncovered



drilled out





Then i cut a small chunk out knowing there was a support between the sill and the body in there somewere



there it is down there



Little did i know not that i was too surprised it was rotten as fook anyway!



so i chopped some more away to see how bad it was



Mmmm another hole in a stupid place to get to



some more chopping



looking sh1t - i could really do with getting in there to repair it properly, i will have to have a think as to what to do.



As it was getting dark i moved inside to get on with some turrets - some steel i bent earlier





cleaned that up



and made a lid out of 4mm



welded the top on the out side





and the inside



then cleaned it off









Thats it for now

James