Kev's workshop projects

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KevJTD
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Location: Lincs

Re: Kev's workshop projects

Post by KevJTD »

Hatchback has some rust, mostly on the inside face but curiously at the top edge, bottom lip looks in great shape. Must have been an issue with the window seal or something.
IMG_20200929_122121.jpg
I didn't fancy breaking the glass as it's a bonded in one on this car so the local windscreen guys took it out for me without drama, a bargain for £20 really considering the hassle of finding another.

Rot, as usual, didn't look any better once all stripped down!
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IMG_20201007_183457.jpg
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Giulietta JTD 170
Lancia Delta integrale
Lancia 2000 Sedan X 2
Clio 172
Lancia Flavia coupe 1.8 1963
Lancia Y10 FIRE LX
Lancia Y10 GTie


I'm bad with people things
But I should have tried more

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KevJTD
Posts: 4594
Joined: Thu Sep 26, 2013 8:48 pm
Location: Lincs

Re: Kev's workshop projects

Post by KevJTD »

Had a few days mulling over the best way to deal with it all, outside face wasn't much more than the flange and a little of the outer face.
Worse though was the rust on the inner face which is all visible once done as they have no plastic cover so needs to look half decent.
Problem is that although the surface looked bad the underside of that surface was equally rusted. So it came down to either having it dipped and hoping something came back, but that would strip all the sealant that's in good order plus any paint from the inside.
I could have it blasted but that wouldn't clean the underside face.
I considered cutting most if not all of the outer skin off so it could be blasted from the inside but that brings it's own challenges and could make more work.

The plan I came up with was to repair the outer skin then cut off the whole section of the rusted inner face so I can put the pieces in the electrolysis tank which is much less harsh than blasting so I've more chance of something being useable..

Outer skin cut out and now you can see the rust inside...
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Repair piece welded in.


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Once the outer skin was stable then it was just a case of cutting all the rusty piece in one lump with care taken to be able to align it easy to refit but also to be able to weld and grind it back..
Attachments
IMG_20201010_172741.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia 2000 Sedan X 2
Clio 172
Lancia Flavia coupe 1.8 1963
Lancia Y10 FIRE LX
Lancia Y10 GTie


I'm bad with people things
But I should have tried more

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KevJTD
Posts: 4594
Joined: Thu Sep 26, 2013 8:48 pm
Location: Lincs

Re: Kev's workshop projects

Post by KevJTD »

Other side was the same process but didn't have to go so far around the corner. But just a little bit which made getting the start of the corner tricky.
IMG_20201010_181450.jpg
No less rust on the inside though..
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Two pieces brought home, welded a few small holes from behind so fingers crossed it doesn't end up like Swiss cheese as there's a lot of detail that's needed..
Attachments
IMG_20201010_184837.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia 2000 Sedan X 2
Clio 172
Lancia Flavia coupe 1.8 1963
Lancia Y10 FIRE LX
Lancia Y10 GTie


I'm bad with people things
But I should have tried more

rsfruitbat
Posts: 583
Joined: Tue Jan 28, 2014 7:54 am

Re: Kev's workshop projects

Post by rsfruitbat »

Hi Kev
Do you cut stuff out with a Dremel as I can't see overcuts and you seem to be able to get right into the corners????
Rsfruitbat

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KevJTD
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Location: Lincs

Re: Kev's workshop projects

Post by KevJTD »

Mostly an electric angle grinder with a 1mm slitting disc in bit for corners I trim it out with an air powered hacksaw.
Also have a smaller air powered grinder with thin discs in so have some options.

Parts have cleaned up nicely today, only created a few more pin holes so at least it didn't fall apart!


Cleaned and painted a few more bits too, despite protestations that it wouldn't be a fussy build... Well, the rear brake drums did look scabby :roll: :lol:
Giulietta JTD 170
Lancia Delta integrale
Lancia 2000 Sedan X 2
Clio 172
Lancia Flavia coupe 1.8 1963
Lancia Y10 FIRE LX
Lancia Y10 GTie


I'm bad with people things
But I should have tried more

User avatar
KevJTD
Posts: 4594
Joined: Thu Sep 26, 2013 8:48 pm
Location: Lincs

Re: Kev's workshop projects

Post by KevJTD »

Pieces cut from the inner face of the rear hatch cleaned up nicely at the weekend so today I got chance to weld them back in, taking care with alignment as the long oblong slot each end holds the fittings for the electrical connections with pins, not unlike the S3 sud hatch.
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I've been meaning to strip the wiring loom out from the engine bay for a while but wanted to label it up better, pencil on masking tape always fades so a better solution was needed.
A half held label printer is the answer. Can't think why I haven't used one before, prints out little labels on self adhesive vinyl strips which loop around perfect, and won't fade!

Engine bay now ready to be prepped for paint, thankfully taking the last few items out didn't reveal anymore work..

Amazing how a simple thing like emptying the bay makes it seem like it's further along all of a sudden, seemed like I wasn't making much progress but now seems very close to the primer stage..
IMG_20201015_161714.jpg
IMG_20201015_192709.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia 2000 Sedan X 2
Clio 172
Lancia Flavia coupe 1.8 1963
Lancia Y10 FIRE LX
Lancia Y10 GTie


I'm bad with people things
But I should have tried more

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KevJTD
Posts: 4594
Joined: Thu Sep 26, 2013 8:48 pm
Location: Lincs

Re: Kev's workshop projects

Post by KevJTD »

One more step done today that I've been putting off as a real PITA job, the front inners wings needed the rubberised underseal taking off back to bare steel.
Thankfully nothing of note under it all, nothing to get the welder out for anyway.
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Etch primed it all including the previous repairs to the rear quarters and bumper mounts then a good dose of the stoneguard which I'll leave for a few days to go off now.
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Really close now to finish off the repairs and get ready for primer 8-)
Giulietta JTD 170
Lancia Delta integrale
Lancia 2000 Sedan X 2
Clio 172
Lancia Flavia coupe 1.8 1963
Lancia Y10 FIRE LX
Lancia Y10 GTie


I'm bad with people things
But I should have tried more

alfadave
Posts: 924
Joined: Sun Jan 17, 2016 6:57 pm

Re: Kev's workshop projects

Post by alfadave »

What will you do with it when its done?

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KevJTD
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Joined: Thu Sep 26, 2013 8:48 pm
Location: Lincs

Re: Kev's workshop projects

Post by KevJTD »

After all the work done Dave I think I will be keeping it, it's not really worth half what I have put into it money wise but it'll be a nice little car for shows etc.
The other Y10 will get more regular use.
This one though is about £100 a year to insure and less than that for 6 months tax so hardly a big expense, and it doesn't take a lot of room up! :lol:

Now I've gone to town and replaced everything, clutch, brakes, shocks etc and all parts refurbed it should be right for a few years yet.
Giulietta JTD 170
Lancia Delta integrale
Lancia 2000 Sedan X 2
Clio 172
Lancia Flavia coupe 1.8 1963
Lancia Y10 FIRE LX
Lancia Y10 GTie


I'm bad with people things
But I should have tried more

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