Outlaw Anglia - took it racing & lifted the wheels!

[blackpopracing]

Thanks Peter. Is the power file air or electric?

A little progress when I got in from work, my 50mm Roloc discs arrived today so I can now grind stuff in corners more easily.

I thought I'd chisel off the filler over the gutter before dinner as the stripper disc had removed 90% of it already. This filler had been done by the rodshop before it came to me but I wanted to see what had been covered up to make sure whatever I paint wont go bad in 6 months.

Oh F*** It's a LOT worse than I expected



What is worse is the rodshop has sprayed over all the suspect(?) areas with some godawful rubbery silicon type underseal that is difficult to remove and will make any repairs 10 times as hard

This is what was bodged over;



You can see the awful grey rubber 5hit sprayed over it in the photo. Pretty pi55ed off with the bodge done here, even the filler was not stuck very well and the gutter was half full of the stuff in lumps.

Not a happy bunny tonight, if you can't do a job properly, then don't do it. This is going to be a pig to fix

I just hope the passenger side is not as bad.

[mk2cossie]

Posting to add i like the progress, but not clicking on the like button for the last post as no one likes to find that

Is the gutter going to require chopping out and replacing as a lump or stitching strips back together in situ?

[kevins]

Pretty grim and a terrible bodge but it's all fixable, just look at what commycoupers been finding on his LT to make you feel better!

[johnthesparky]

Thanks for sharing

[crockpot]

I'm sorry I asked now☹️
Repairing that will keep you occupied for a while.
Shocking bodge, I would be having words about that if I had paid for that.

[blackpopracing]

Thanks all.

Cleaned it up as best I could on the inside, but access is pretty restricted If it was not for the grey rubber 5hit sprayed all over it it would be basic finger sanding.

Passenger side not quite as bad, but its not too good.



Drivers side cleaned a bit;



as was passenger side;



Passenger side outside;





To console myself I stripped the whole of the passenger side of the car;





That's the whole car stripped now apart from door returns, door inner edges, bootlid gutters & roof gutters.

Then had another look at the roof. I pondered drilling out the spotwelds and removing the gutter, but I've heard that this often destroys the gutters.

Then I though about maybe spotwelding a shaped bit of steel behind it after chopping out the worst of the rust. This still would be really difficult to weld though and there is a lot of lead loading right by it.

I think I'm going to take the easy route and do a modern 'bodge' on it. I think with a lot of cleaning up and very careful removal of the top layers of rotten metal and a intensive dose of Hydrate 80 that using modern epoxy panel bonding adhesive I can bond new steel inside the roof to make it solid again. This avoids the welding and lack of access to grind welds back - not to mention any distortion and the fact that the metal is paper thin.

The gutters themselves are in really good condition, its the bodywork behind them that has rotted so although it's not a perfect solution it should be good enough to last another 20 years if I do it properly.

45.5 hours

[petervdv]

Mark, the Makita is an electric one. www.gereedschapcentrum.nl/makita-9032-stripschuurmachine-500w-9-x-533mm.html?gclid=EAIaIQobChMI_pTMvKu07wIVCLp3Ch2URA2bEAQYASABEgKW6_D_BwE

There are wide sanding belts with the same length which i cut in 8 small belts otherwise it would be expensive.

Peter

[blackpopracing]

Thanks Peter. I think we have one of those at work - I can borrow it

[Deleted]

Enjoying this, thanks for sharing.
Re the awkward to reach areas.
I use these disc wire brushes.
Not this might sound odd but get the el cheapo ones.
They don't last long but they are much less stiff and can be forced in to gutters and corners. I run the drill as fast as it will go and they do save a lot of tedious work in the narrow spots. Hold on tight!

[blackpopracing]

^^ yep, got a box of various ones of those that can fit the angle grinder. They can also fit my polishing mop which I can run slower as 14,000 rpm makes nice missiles from those bristles!!

[blackpopracing]

My 50mm Roloc discs arrived today so I could sand the welds on the last bit of bulkhead repair at last, not perfect but nothing a thin skim of filler wont fix.



I tried folding a couple of strips of steel at work today - this was done purely from guesswork as I took no measurements last night.





Not a bad guess! needs a longer leg for the lower part but pretty close for a trial go. I can use my new shrinker stretcher to put a curve in it to match the body.



Tonight I'll have a go at carefully cutting the rot out on the outside without cutting the inner roof skin.

[blackpopracing]

Tonight was spent cleaning up the rotted areas, all the awful gunge was stripped off the inside back to bare steel and the outside was carefully attacked with the 1mm cutting disc to slice out the expanded rotted out gutter skin to expose the rotted roof layer underneath.

This was then stripped back with a big rotary wire wheel dug in as hard as I could to remove all the loose rust and any caked in rust. The roof channel also received this treatment - exposing yet more filler stuffed in rust holes and covered in the grey rubbery gunge again

The whole lot got treated with a good dose of Hydrate 80 worked into all of the nooks and crannies.

48 hours

[ivanhoew]

Golly .

[blackpopracing]

Golly indeed Robert.

Been doing research and 3M do a nice structural bonding adhesive that will be total overkill to do the roof repairs. Will need to get some ordered.

I also got a little box of electrical components today for the wiper delay - did not realise it was a self assembly circuit board kit, still - it will be fun to make.

[ivanhoew]

I'm sure you would have thought of this mark , but just in case , does that 3m stuff stay good in hot weather heating up the steel roof .

[blackpopracing]

Robert, its the stuff they glue cars together with nowadays rather than welding, so I reckon a couple of little steel strips won't challenge it very much!

[thomge]

Except for the latest horror, the pop is looking great. Was there any consideration of deguttering it after finding that mess? I have no experience to base this on but I imagine it could make the repair ‘easier’.

[blackpopracing]

Hi thomge, not really no.

De guttered pops (to me, & I expect Phil as well) look awful, it makes the rear of the roof look humpbacked as there is no gutter line to break up the profile. Also the gutters are there for a good reason, the doors are not watertight (well mine are, lol) so de guttering means a very wet inside of the car.

Tonight I'm having a break as the ecxzema on my hands is driving me nuts (caused by cold/over washing & wearing nitrile gloves)and I'm playing electronic lego

The wiper delay kit arrived and it's in self assembly form, so soldering iron is out!

[blackpopracing]

And all assembled, just need to test it now.



48.5 hours

[llwynogmon]

I sympathise with your hand problem, this stuff works for me.