My new project, finally got my integrale.

[KevJTD]

Popped down there this afternoon after work to make up a bumper mount for the side guide, made up a little box that I could attach to the car but would importantly be in the right position 3D wise to hold the bumper side where it wants to be!

Tacked it in place with the bumper on so it's positioned so I have a little adjustment

Nice strong mount now which should hold the bumper up

[KevJTD]

On to the passenger side next time......a few gaps to bridge!

[Kegsti66]

Great stuff Kev, really cracking on well there.
Putting the rest of us to shame

[Johnboy]

Great stuff Kev, really cracking on well there.
Putting the rest of us to shame

Totally Agree

[KevJTD]

Ever had that one step forward, two steps back kind of day?

It's been bugging me for some time to be honest, the inner part of the used rear wheel arch I fitted to the passenger side at the beginning a year or two ago has some surface rust on it. I did originally sand and grind it down, put some rust stopper on it and left it to see what would happen. It's been a year or so since I fitted it (yes, been doing this one for a while already!) so has had chance for anything to develop, a bit harsh a test as has been left pretty much unprotected. The rust pitting I didn't want to go through the whole process of cleaning it again as it would bug me that I could do better.... So resigned myself to take a backwards step and start undoing some previous work.

Started slicing it down, the pitting is evident

Cut it all off which revealed the top portions underside to be in great condition much to my relief, the underside of the portion removed wasn't really that bad but it's gone now so happy enough.

Whilst I had some movement in the arch I reinforced it all against the rear floor to better align it as the door wasn't quite shutting as well as could be, asolid base now for the rest to be built off.

A new inner panel then was made up with a folded return to attach inside the car at the arch lip.

Still a bit of a gap to construct panels for inside the car but at least I am about back to where I started the day! These cold days are no good for progress, too tempting to start late and go home early...must try harder on Saturday to make some progress although I am happy I did this rather than worry about leaving a potentially rusty panel in a vulnerable area like the inner arch.

[rsfruitbat]

Incredible commitment to doing the job right Kev.

Rsfruitbat

[KevJTD]

Yes, it's hard at times to keep going Ade mate, as I'm sure you get on days with the rally car. The temptation to get it done as quick as possible is sometimes hard to resist but I really don't want to be in the position in a few years that rust is breaking out somewhere due to corner-cutting at this stage.

One day it'll be done and worth all the days off work spent in a near freezing point cold workshop

Kind words and praise are very much appreciated as always mate, thanks very much. What helps make it worthwhile

[junior]

Your wise to go back while it is clear to do so. Esp if its bothering you.

I am already planning a revisit to a couple of tasks on mine and will have to take stuff off to do it which is annoying .

The cold is putting me off more than you though as I have not started in the shed yet, bar brushing the snow off that got in under the roof.

[KevJTD]

The cold is a real turn off mate, that's for sure. Only limited time on the car at the moment as hovering around zero isn't ideal for fingers and toes!

Anyway, did manage to get 3 hours or so on it this afternoon so the step repairs got finished off then the inner arch could finally become part of the car again!

[Kegsti66]

It is all good progress.
As we all know, they are never "really" finished.
Top marks for slogging on .

[KevJTD]

Christmas out of the way so the integrale is getting some much needed attention to keep things ticking along.
I did actually do a few hours over the festive period but didn't update, bit more done today.

As the passenger side boot floor needed rebuilding the first job was to do the rear panel outer edge lip to match the drivers side, I did mean to post this bit actually just to show what is meant by "plug welds" for those interested to know..
The technique is handy when you haven't a spot welder to hand and want to join 2 flat faces together, you drill or punch holes in one section then weld through that hole to the other piece, so you fill the hole with a puddle of weld, which it is sometimes called puddle welding.

Once all the holes are filled in the top edge got seam welded in small tacks then ground back, after that the fold was knocked over fully so the water drips fall off instead of going into the seam

The last job I did on that trip was to have a look at the boot corner that needed replacing, awkwardly it has some holes for the fuel lines to go through..

The task then was to make a template out of card then copy that in steel..

[KevJTD]

Today I had a look at the chassis section that I thought wasn't too bad......but it wasn't really good enough to leave so the side got some bits chopped out

A repair section was made up and fitted in along with the corner near the outrigger getting new metal too, then the plate I previously made was lined up and added in

The remaining hole then got plated over and the lower section of the inner arch filled in.

[KevJTD]

A good day at last, pleased with the progress for a change!

Started making a repair section for the outrigger then repairing the bottom edge of the inner 1/4 panel, amazing how these little repairs instantly put strength back into things.

Next bit along is the outer quarter where it had been repaired before with a riveted on panel.

A new outer section was made up and with some careful alignment it got welded into place, an easier task this side as I've already figured it out on the other side.

The rest got boxed in then to just about finish this corner off

Just requires the bumper mount bracket making up but I haven't got around to sorting the broken guide on the bumper itself yet so hoping there's one on the spare bumper I saved from the HF turbo I recently chopped up...

Pleased with the days welding, some tricky and time consuming bits to make but I can finally start to think that the welding is nearing an end.....

[Johnboy]

Wow really coming on now kev .

[Kegsti66]

You just continue to blow me away with your "just made a new bit" way of tackling these jobs Kev.
It is looking great and nothing seems to phase you.
Top man.

[KevJTD]

Cheers for the encouragement guys, much appreciated as always.

I'm getting a bit more confident now to tackle these jobs if I'm honest, beforehand it was a case of having to do it myself or scrap the project as I can't afford to pay someone else to do it or buy one already done so I have had to continue to learn as I go along. The course I did last year at the fabrication place though was the turning point, learnt so much on that course.

I am getting to the point now Keith that it doesn't seem to phase me too much anymore

[junior]

[quote="KevJTD"]I am getting to the point now Keith that it doesn't seem to phase me too much anymore!

Well that might just be all the practice you have been having.

[KevJTD]

you could be right there mate

[KevJTD]

any ideas what this flat piece will turn into?

[KevJTD]

as it's not in the guessing game thread I'll reveal all

in it's position..

finally the rear bumper is aligned up in all areas so as the rear quarters are where they will stay at then the car is almost ready to have the rollover jig attached..

I've a little more repairs to make in the front of the arch to box the sill in then i'll do a bit more repairing to the turrets before stripping all the doors etc off, may even be able to think about stripping, sealing and painting the underside soon...

[Kegsti66]

A closing wheel arch for a Lancia/Alfa 155?
Surely you haven't started on Tim's 75
I am sure what ever it is , it will be great.

[Kegsti66]

Bloody 'ell Kev, you hardly gave me a chance to answer wrongly !!

[Johnboy]

Wow great progress kev . Top welding as always . I think the grale will be flying back to Italy in 2019

[KevJTD]

didn't expect anyone to guess so quickly mate! sorry

you were right though, bound to be an alfa/Lancia bit of some sort

the 75 won't get started for some time mate, his Sud shell will be done first.
plus the 'grale will need finishing welding this year...and the 155 needs finishing and painting the rear arches and mot'ing....and the imp needs finishing....so 2019 for the integrale isn't really gonna happen JB, still got the mechanicals to overhaul yet....

[KevJTD]

Decided to do a bit more strengthening work to the rear turret before it goes on the tilter, at least the rear part anyway, the top section I'll do once it's able to be rotated to make access easier.

A couple of repairs later and the inner part is done, the bit inside the wheelarch will get done when it's not so awkward to weld.

It has to be a little bit accurate there as the fuel filler & evap unit thingy sits there..

Boxed in the rear of the sill and made up the remains of the chassis section so it's almost ready to go on the tilter. Should be a couple of visits to finish a little more off then once I can get it to rollover I'll start stripping the underside ready to seam seal it all and ready for etch and stoneguard.

[Kegsti66]

Well it looks like it fits mate, so it was accurate enough.
Top job.

[KevJTD]

No progress on the car this week, did have a ride out this afternoon over the Humber Bridge to fetch a complete rear axle set, just for the diff carrier really but no harm in having spares
Hubs seem better than mine too so may end up using a few bits off it, discs are like new so although they are really cheap to buy I'll put these ones in grease bags and use them

[junior]

Hope you have the rollover jig already. One of my chums got to your stage, went to buy one second hand and

bought the TR7 that was already on it as well. Doubled his work load.

Keep going, crocus are up so spring is on its way now despite the present temps.

[KevJTD]

always something out there to tempt, eh

[KevJTD]

At long last I've declared the car welded enough to get it up on the tilter, I can then finish off the harder to get to bits like the rear strut towers.
I've still got the windscreen scuttle to change but I'll do that once I get the car lower down on its' wheels again, it's just too high up at the moment to be comfortable.

So once I'd sorted out where all the mounting points were for the sill covers I set to and stripped the doors and windscreen out. Wiring and a few bits are yet to come out, I really need to label it a bit before it goes into a big pile!

Windcsreen corners are a bit crusty at the bottom edges, not bothered though as I have a very good one to fit which will rid all these bits