Sud hatch repair

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KevJTD
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Sud hatch repair

Post by KevJTD »

I've had the hatch belonging to Lou with me for a little while now needing the usual corners repairing, so it's ready to be used I thought it about time to get it done.
It had been previously repaired which wasn't really good enough as there was no recess for the window seal to sit in so a fresh start was needed.
IMG_20200720_120659.jpg
The end result is this...
IMG_20200819_173011.jpg
Sounds and looks simple?
The reality was with the complex creases and angles that repair took me about 4 or 5 hours, mainly time spent making a jig to create the folds....
This is how it was done..
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

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

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KevJTD
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Re: Sud hatch repair

Post by KevJTD »

Started off with a 4" square piece of mild steel, section needed for the top face marked off and folded, that's the easy step..
You'll notice in the next picture the folded section which is sat on the base of the jig I made, just some 2mm steel welded together.
IMG_20200819_112016.jpg
Next step is to use another flat section of the steel to trap the angle up against the welded top edge, like this..
IMG_20200819_121813.jpg
Then fold the piece forward making sure of a flat crisp edge, keep the piece tight in the jig. Could have drilled the halves and pinned it but I'm confident enough now to not have to, especially on bodywork thickness steel like this .9mm stuff.
You'll end up with this..
IMG_20200819_122016.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

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

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KevJTD
Posts: 5107
Joined: Thu Sep 26, 2013 8:48 pm
Location: Lincs

Re: Sud hatch repair

Post by KevJTD »

Next step is the tricky bit, you need to create the fold which will be the width of the channel where the seal will fit before it angles down to the flange.
This part of the jig was 2 pieces of 2mm steel welded together at the correct distance to match the width needed. Confession, first attempt was about 1mm too small so it didn't quite look right so the jig needed cutting apart and remaking, thankfully carefully measuring meant 2nd time success!
This is the top of the jig with the step visible, it sits the other way up to be used.
IMG_20200819_122031.jpg
When clamped down the jig looks like this, ready for the return to be folded allowing for the seal channel width..

IMG_20200819_125824.jpg
IMG_20200819_125630.jpg
Start to bring the piece up to an almost right angle, doesn't need to be a full 90 deg bend but more than this demo pic shows..
IMG_20200819_125844.jpg
You then have to make the final fold for the flange joint, this I did by clamping between two flats rather than making anything fancy..
Which gives you this.
IMG_20200819_141720.jpg
So a fairly complex piece with regards to the tight folds can be made with a little effort and imagination.
Other side won't take half as long as most of the time spent was making the jig, might hang onto the pieces rather than chop them up and reuse incase I get anymore to do! :D
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

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

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LooLooSud33Spider
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Re: Sud hatch repair

Post by LooLooSud33Spider »

Superb Job Kev your efforts are appreciated 😃
Alfasud Ti 1984
Alfa Spider 2.0 Ts 916
Alfa Spider 20v Turbo

Alfastrut
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Re: Sud hatch repair

Post by Alfastrut »

Nice looking repair kev

rsfruitbat
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Re: Sud hatch repair

Post by rsfruitbat »

Hi Kev

as its such a common problem Kev I suspect there would be a market for that as a repair panel.
I'd make a few up and flog them on fleabay.

Now you have done all the hardwork fabricating the jigs you deserve to get some benefits from it.

How much is a solid S3 hatch worth these days?

Cracking job Kev. Hope the bellies getting better?

rsfruitbat

Sud 145
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Re: Sud hatch repair

Post by Sud 145 »

Super job Kev - literally just found these pics from 10yrs ago.
P2150217.JPG
P2150218.JPG
P2150227.JPG
P2170253.JPG

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KevJTD
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Re: Sud hatch repair

Post by KevJTD »

Other side done today, inner section needed a bigger repair which meant recreating the square etc. All the same ideas.
Attachments
IMG_20200820_141929.jpg
IMG_20200820_153217.jpg
IMG_20200820_153315.jpg
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

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

User avatar
LooLooSud33Spider
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Joined: Mon Dec 05, 2016 11:14 pm
Location: Staffordshire

Re: Sud hatch repair

Post by LooLooSud33Spider »

Superb quality work as always Kev
Alfasud Ti 1984
Alfa Spider 2.0 Ts 916
Alfa Spider 20v Turbo

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KevJTD
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Re: Sud hatch repair

Post by KevJTD »

Belly healing nicely thanks Ade, scabbed over nicely and predictably itchy, I won't offend by showing a picture!

I could make more repair sections if anyone wants them, for a donation to the forum upkeep to keep us online..

viewtopic.php?f=56&t=2243

Say £20 for a pair of repairs + £5 for UK postage.
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

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

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LooLooSud33Spider
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Location: Staffordshire

Re: Sud hatch repair

Post by LooLooSud33Spider »

I’d say that’s an absolute Flippin bargain Kev. £20 for quality Hand made repair sections that You know Will actually Fit. I Know id defo order a pair but my hatch Is now in brill condition. Knock a pair up and take a picture And post in parts for sale.
Alfasud Ti 1984
Alfa Spider 2.0 Ts 916
Alfa Spider 20v Turbo

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KevJTD
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Re: Sud hatch repair

Post by KevJTD »

I'll do that Lou, see if anyone wants any..
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

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

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LooLooSud33Spider
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Joined: Mon Dec 05, 2016 11:14 pm
Location: Staffordshire

Re: Sud hatch repair

Post by LooLooSud33Spider »

This pic shows the superb quality of the fit
9CFCF41B-95B9-486E-8DD4-20620963CA74.jpeg
9CFCF41B-95B9-486E-8DD4-20620963CA74.jpeg (38.33 KiB) Viewed 6776 times
Alfasud Ti 1984
Alfa Spider 2.0 Ts 916
Alfa Spider 20v Turbo

NEG
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Re: Sud hatch repair

Post by NEG »

Seriously, you have some skills there Kev

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Johnboy
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Re: Sud hatch repair

Post by Johnboy »

That's brilliant . As Darth Vader would say . Impressive, most impressive :D
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