Kev's workshop projects

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KevJTD
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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!
Attachments
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IMG_20201007_183438.jpg
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
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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...
IMG_20201010_165216.jpg
Repair piece welded in.


IMG_20201010_171920.jpg
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
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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..
IMG_20201010_174452.jpg
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
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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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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

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KevJTD
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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.
IMG_20201015_144050.jpg
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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
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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.
IMG_20201016_164658.jpg
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.
IMG_20201016_182127.jpg
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
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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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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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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Bit of an update.
A few guys wondered if I'd been busy, I have made good progress and have reached the point where I wanted to be at now.

Hatch repairs went well enough, filler shaped to match the window.
IMG_20201022_161723.jpg
IMG_20201022_161428.jpg


Car all straightened out and primed..
Attachments
IMG_20201030_170418.jpg
IMG_20201030_170524.jpg
IMG_20201030_170512.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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LooLooSud33Spider
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Re: Kev's workshop projects

Post by LooLooSud33Spider »

Great work as always Kev
1955 Austin A30 “S”
1973 Mg Midget
1983 1350 Sud Ti (soon to be 1500)
1996 33 1.7 16v racer
1997 916 spider 20v Turbo racer
2006 Porsche Cayman S
2006 Peugeot motorhome
2012 Skoda Octavia Vrs

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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Choice then was what to do with the rear panel and hatch which should have been in satin black originally.
Conversations with my paint rep and great advice as always from Keith sort of gave me an inkling of which way to go. Using different clearcoat to make the rear bits satin but still lacquered sounded interesting but overly complicated for my first time at properly using basecoat and clear, apart from rattle can jobs.

Used an old section of sill to have a look at what it would turn out like
IMG_20201102_142906.jpg
With that settled in my mind and a plan laid for the 3 stage painting it went OK, apart from running out of gas at the mid stage putting the blue basecoat on... That's another story... Runs sorted once back from Louth for more gas..

Once the dust was flatted out and polished up I'm happy enough with it, marks in the clear are just what I have to accept with the poor spraying conditions.
Attachments
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IMG_20201107_184856.jpg
IMG_20201107_184829.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
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Re: Kev's workshop projects

Post by KevJTD »

Repairs around the grilles blended in OK, wheel arches blown in too.

Long process of putting back together can take it's time now, given myself until end of Feb so shouldn't be a problem.
Attachments
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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

Kegsti66
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Re: Kev's workshop projects

Post by Kegsti66 »

Great stuff Kev, you have been busy, as usual.
Will look great when it is all back together.

junior
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Re: Kev's workshop projects

Post by junior »

It almost looks like you have done this before. Good effort esp while a lot of people are feeling rather down. :D

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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Now the paint is on I can relax a bit more, getting stuff ready to be refitted now although a lot of stuff is ready now.
One thing that needs to go back on first is the fuel tank and that needed some new straps making.
Some strips cut from 1.6mm steel, folded to size with washers welded to the fixings for reinforcement and it should do the job.
IMG_20201114_191801.jpg
I'll give it a final clean up tomorrow and paint with hammerite, should be good for another 20+ years then.
IMG_20201114_191708.jpg
Also got a few bits to clean and prep, steering rack for one which will get a clean up plus new gators and track rod ends. As it's a manual rack a good internal greasing will be beneficial too!
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
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Re: Kev's workshop projects

Post by KevJTD »

Autoglass came and fitted the new 'screen as promised, rear hatch glass fitted too.
IMG_20201123_114304.jpg
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Time to start building stuff up.
Fuel tank straps got a strip of neoprene glued to the painted side that sits against the tank s it doesn't chafe the paint and start rusting.
Axle was pretty much ready for fitting having been built up a while ago. Still took ages to clean and sort all the bits and pieces such as bumpstops and spring plates that needed painting.
New shocks etc and looking complete under there.
IMG_20201125_174820.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
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Location: Lincs

Re: Kev's workshop projects

Post by KevJTD »

Onto the front end and the engine bay started to come together with all the refurbished bits going on.
IMG_20201124_183320.jpg
A few engine mounts deserved to be cleaned and painted before going in to keep it looking tidy.
Engine and gearbox went in without much drama.
IMG_20201126_190041.jpg
New front struts got built up with all the refurbished parts, ready for fitting.
IMG_20201128_125326.jpg
Front suspension and brakes all bolted up, new bushes etc in all parts.
IMG_20201130_192409.jpg
IMG_20201130_195756.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

alfadave
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Re: Kev's workshop projects

Post by alfadave »

The suspension rods look stronger and more durable than the Sud fabricated types.
I presume they just needed painting/ re bushing.
From a different era I suppose?

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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

More progress this week as a rare few days off work between Christmas and New Year allowed me to get cracking, be nice to see it all done by the end of the week.
Dash needed some repairs around some known vulnerable areas.
All suspension finished off, break lines run and bled, engine all plumbed up and running a treat.
IMG_20201219_230341.jpg
IMG_20201219_230416.jpg
All glass now in, doors aligned, hatch back on, bonnet and wings etc.
I fitted an aerial as the car has never had a radio fitted but had the hole in the roof, a dab/din one will allow a choice of head units.
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Just the interior to finish off now, carpets, seats, roof lining etc.
Another one nearly saved 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

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LooLooSud33Spider
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Re: Kev's workshop projects

Post by LooLooSud33Spider »

Stunning work as always Kev
1955 Austin A30 “S”
1973 Mg Midget
1983 1350 Sud Ti (soon to be 1500)
1996 33 1.7 16v racer
1997 916 spider 20v Turbo racer
2006 Porsche Cayman S
2006 Peugeot motorhome
2012 Skoda Octavia Vrs

junior
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Joined: Fri Dec 19, 2014 7:43 pm

Re: Kev's workshop projects

Post by junior »

Fantastic work. Impressed with the rate you do it at as well. Keep safe. :D

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