Kev's workshop projects
Re: Kev's workshop projects
Has anyone ever taken on a restoration that required less work than was anticipated?
Your a real inspiration Kev. Reading your posts, and others, motivates me to get back into the garage.
Your a real inspiration Kev. Reading your posts, and others, motivates me to get back into the garage.
1976 1.5Ti
1977 1.2Ti
1989 1.7 Sprint Veloce
1989 75TS
2003 147 2.0TS Lusso
2004 MX5 1.8S
2002 1.6 Focus LX
1977 1.2Ti
1989 1.7 Sprint Veloce
1989 75TS
2003 147 2.0TS Lusso
2004 MX5 1.8S
2002 1.6 Focus LX
Re: Kev's workshop projects
Glad it's appreciated mate, I do still wonder if it's madness or bloody mindedness or just plain stupidity but I do like the underdog...
So much so I've just done a deal to get my old Y10 GTie back off Richard, it'll be getting the same treatment in the future..
So much so I've just done a deal to get my old Y10 GTie back off Richard, it'll be getting the same treatment in the future..
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
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
Re: Kev's workshop projects
Passenger side all welded up now, happy with the outcome.
Fitment around the light is decent.
Onto the other side now, pretty much identical amount of work needed so as I've done one side now then it's easier second time as you know what needs chopping out and where..
Hey presto!
Fitment around the light is decent.
Onto the other side now, pretty much identical amount of work needed so as I've done one side now then it's easier second time as you know what needs chopping out and where..
Hey presto!
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
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
Re: Kev's workshop projects
Bumper bracket reinforcer had more rot at the top end than I'd like, especially as this side bracket is also the towing eye, so a new top half will be made.
Underside has some surface rust which the electrolysis method will sort out.
Should be able to get 3 full days on the car next week so I need my arse kicking if this side isn't done and I'm chopping the windscreen surround out..
Underside has some surface rust which the electrolysis method will sort out.
Should be able to get 3 full days on the car next week so I need my arse kicking if this side isn't done and I'm chopping the windscreen surround out..
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
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
Re: Kev's workshop projects
Good news on the windscreen is Autoglass have got me one on order and can do it through my insurance once I'm ready for it.
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
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
Re: Kev's workshop projects
Made a start on the drivers rear quarter today, had to dig through the same amount of layers as the other side before finding solid steel again. But I got there.
Repaired the reinforcer bracket as before, then made and fitted a new inner lower repair section.
The bumper bracket wasn't so good as I mentioned before, only the bottom half was salvageable but at least that was the important bit. Made up some strong sections and spot welded before seam welding them together, this side is also for the towing eye so needs to be strong..
Repaired the reinforcer bracket as before, then made and fitted a new inner lower repair section.
The bumper bracket wasn't so good as I mentioned before, only the bottom half was salvageable but at least that was the important bit. Made up some strong sections and spot welded before seam welding them together, this side is also for the towing eye so needs to be strong..
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
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
Re: Kev's workshop projects
Had time then to make up the outer skin, curved at the bottom as before using the same cardboard template.
Alignment gained using the rear light unit which after all is what needs to be right.
Got tomorrow on the car so I'll make up the inner sections before the outer gets welded into place.
Alignment gained using the rear light unit which after all is what needs to be right.
Got tomorrow on the car so I'll make up the inner sections before the outer gets welded into place.
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
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
Re: Kev's workshop projects
Inner section repaired, which again was a bit awkward as you need to make a section blind, behind the outer section so it kept having to be taken off and gradually make the inner bits.
Eventually though it all lined up so once that was welded into place the outer skin could go on.
Trial fitting of the bumper and lights came as a relief that it all lined up just nice! All the measuring and template making paid off.
Next visit I get to start the windscreen surround repairs... Should be nice!
Actually it shouldn't be too bad a problem, apart from the section with the vents in, hoping that doesn't stretch down the "fingers"..
Eventually though it all lined up so once that was welded into place the outer skin could go on.
Trial fitting of the bumper and lights came as a relief that it all lined up just nice! All the measuring and template making paid off.
Next visit I get to start the windscreen surround repairs... Should be nice!
Actually it shouldn't be too bad a problem, apart from the section with the vents in, hoping that doesn't stretch down the "fingers"..
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
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
Re: Kev's workshop projects
Lowered the car down a bit now so I can get at the windscreen surround.
Trying to figure out how to make a repair section where the vents are, tried a few ideas but none successful enough, have come up with a new plan to make another jig.. Another time.
With that in hand I started on the easier section, relatively speaking. The 'screen flange section curves in a couple of directions so not a simple folded repair as it all needed to be shaped so more sections to allow for manipulation.
Looked a bit grotty even before the' screen came out. I'd put some silicon in there in an attempt to keep rainwater at bay..
Section of rusty bit cut away, new repair piece awaiting welding.
Then infill the triangular hole and a bit around the bottom corner, that's one section done!
Trying to figure out how to make a repair section where the vents are, tried a few ideas but none successful enough, have come up with a new plan to make another jig.. Another time.
With that in hand I started on the easier section, relatively speaking. The 'screen flange section curves in a couple of directions so not a simple folded repair as it all needed to be shaped so more sections to allow for manipulation.
Looked a bit grotty even before the' screen came out. I'd put some silicon in there in an attempt to keep rainwater at bay..
Section of rusty bit cut away, new repair piece awaiting welding.
Then infill the triangular hole and a bit around the bottom corner, that's one section 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
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
Re: Kev's workshop projects
loverly jubbly. Nice work Kev, can see this wanting on my Sud as maybe mentioned b4.
Re: Kev's workshop projects
If there's any sign of rust, or even bubbling paint mate it'll be as bad I'm afraid.
All sortable though
All sortable though
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
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
Re: Kev's workshop projects
Nice work Kev. I really need to get my screen out and just get on with it. It's the last bit of welding I need to do before it gets a respray
Re: Kev's workshop projects
Just get rid of the LH vent altogether (some paint runs there?)
The RH one looks ok.
Passenger can open the LH window for ventilation!
The RH one looks ok.
Passenger can open the LH window for ventilation!
Re: Kev's workshop projects
That did occur to me Dave
Yes, it's had paint before, it best get used to having the runs
Yes, it's had paint before, it best get used to having the runs
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
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
Re: Kev's workshop projects
In fact, get rid of both vents to even it up!
Air will get to the heater somehow.
Air will get to the heater somehow.
Re: Kev's workshop projects
Nice idea in a way, would stop rainwater getting in, but also it would most likely force air for the heater to be drawn in from the engine bay which is far from ideal.. Sleepy time
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
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
Re: Kev's workshop projects
Started on my trip around the windscreen surround today, drivers side pillar first job.
Most of it cleaned up pretty well, knotted wheel and grit blaster did most of the work. Small bits to weld so a decent result really.
All welded up, loving my spot welder
Top section was god all the way across after all the cleaning, bingo
Passenger pillar wasn't too bad, just a couple of bits needed welding.
Just the passneger bottom corner then the bit around the vent...
Most of it cleaned up pretty well, knotted wheel and grit blaster did most of the work. Small bits to weld so a decent result really.
All welded up, loving my spot welder
Top section was god all the way across after all the cleaning, bingo
Passenger pillar wasn't too bad, just a couple of bits needed welding.
Just the passneger bottom corner then the bit around the vent...
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
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
Re: Kev's workshop projects
Coming together mate.
Could you cut the vents out of another car or bonnet that look similar?
Could you cut the vents out of another car or bonnet that look similar?
Re: Kev's workshop projects
I did consider going around the local scrapyard with a saw..
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
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
Re: Kev's workshop projects
Run some fresh air to the heater with ducts from the inner wing area?
Re: Kev's workshop projects
I'd tried making a jig to make a section with the slots, almost works and on reflection I know how I could make it work by trapping the steel between two jigs rather than trying to form it using just an underneath jig..
All academic now, had to grow a pair and just get on with it
All academic now, had to grow a pair and just get on with it
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
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
Re: Kev's workshop projects
Cleaned the panel back as far as I dared whilst keeping the shape of the vents, thankfully the rust stopped short of going in the curves but didn't leave a lot of material to weld to.
Plate made up with the necessary curves to follow the curved screen flange in both directions, not easy in a patch that is folded twice as the central piece needed to curve, but it got manipulated enough in the end.
Then the shape cut to match the remaining piece of bulkhead..
Welding was very gently done in small dabs, overlaid to allow it to melt down into the joint.
Equally careful grinding back as all too easy to take away the surrounding material, thin areas got re-welded.
Plate made up with the necessary curves to follow the curved screen flange in both directions, not easy in a patch that is folded twice as the central piece needed to curve, but it got manipulated enough in the end.
Then the shape cut to match the remaining piece of bulkhead..
Welding was very gently done in small dabs, overlaid to allow it to melt down into the joint.
Equally careful grinding back as all too easy to take away the surrounding material, thin areas got re-welded.
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
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
Re: Kev's workshop projects
With the hard bit done the rest was straightforward enough, curved corner needed care to keep the shape so the new screen will fit..
Friday I'll make a start on the drivers door, the last bit of welding...
Friday I'll make a start on the drivers door, the last bit of welding...
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
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
Re: Kev's workshop projects
Drivers door had a scab on the outside and some rust on the bottom plate, nothing too serious you'd think
On looking inside the door though it was clear the bottom plate rust carried on into the seam, the outer section peeled back confirmed that.. Nothing for it but to cut the full length of the outer skin off.
On looking inside the door though it was clear the bottom plate rust carried on into the seam, the outer section peeled back confirmed that.. Nothing for it but to cut the full length of the outer skin off.
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
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
Re: Kev's workshop projects
Bottom plate repaired including further around the forward edge up towards the door card aperture.
Then the new outer skin repair being lined up with the door and wing back on the car so it can be fitted in the correct place, located with clico fasteners so when the door comes off for fitting the plate the location is easily repeated.
All welded into place to the skin and folded with sealant along the bottom edge.
Getting to the point where the welder can have a rest now, think there's a bit on the hatch but that's the last...
Then the new outer skin repair being lined up with the door and wing back on the car so it can be fitted in the correct place, located with clico fasteners so when the door comes off for fitting the plate the location is easily repeated.
All welded into place to the skin and folded with sealant along the bottom edge.
Getting to the point where the welder can have a rest now, think there's a bit on the hatch but that's the last...
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
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
Re: Kev's workshop projects
Looks good Kev, - how do you weld the full length of the door without it buckling ??
John.
John.
Re: Kev's workshop projects
I dont'! It distorts even just using small tacks, just have to accept it and try and straighten it out as best you can.
On the fabrication course I went on a few years back I asked the guy how he'd stop distortion when doing door bottom repairs. He answered by saying he wouldn't ever repair a door bottom as distortion is impossible to prevent, he would make a whole new door skin instead!
One solution pointed out to me by my friend Chris whose Dad restores Capris' is to use a spot welder on the joggled flange which I agreed would be much more resistant to warping and potentially a stronger join as appose to welding one edge. I need to get some different arms for mine to allow cranked finger type arms to get into the tight spaces.
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
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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- Posts: 774
- Joined: Tue Jan 28, 2014 7:54 am
Re: Kev's workshop projects
Hi Kev
Brilliant work as always Kev.
I was wondering what the right sequence is to cover freshly welded areas.
Zinc primer, seam sealer, stonechip, paint, or something else, or what would you swap round / exchange.
Rsfruitbat
Brilliant work as always Kev.
I was wondering what the right sequence is to cover freshly welded areas.
Zinc primer, seam sealer, stonechip, paint, or something else, or what would you swap round / exchange.
Rsfruitbat
Re: Kev's workshop projects
My method, which I am not saying is gospel just what I do, is once something is welded it needs to be coated ASAP as a freshly welded joint will rust in hours.
Etch primer is good but red oxide or similar works well enough, make sure the surfaces are roughed up so it will stick, shiny surfaces will let the paint flake off.
After that the inner surface really needs to be seam sealed if reachable to prevent moisture getting in through any pin holes in the weld joint, or if access isn't possible then I use stoneguard which will do a good job at sealing it.
Outside face of the weld I put a thin layer of fibre glass filler as its waterproof before using regular body filler for shaping.
Important bit is preventing moisture getting into the repair in the future.
Etch primer is good but red oxide or similar works well enough, make sure the surfaces are roughed up so it will stick, shiny surfaces will let the paint flake off.
After that the inner surface really needs to be seam sealed if reachable to prevent moisture getting in through any pin holes in the weld joint, or if access isn't possible then I use stoneguard which will do a good job at sealing it.
Outside face of the weld I put a thin layer of fibre glass filler as its waterproof before using regular body filler for shaping.
Important bit is preventing moisture getting into the repair in the future.
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
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