[Car_Upgrade] 1.9 Gti Rust Repairs And Bodywork

[NFS 32]

Come on mate, looking forward to seeing another miami restored in the same workshop/DIY situation as im in

[johniban 59 1 Cars]

It will be sorted hopefully sooner than later, if i can stop myself from bidding on series 2 land rovers that is!

[johniban 59 1 Cars]

So im near enough all moved into the new unit, both cars are in, the other guy i share with rarely comes down, hes only got to replace the engine, doesn't bother me tho.

[johniban 59 1 Cars]

So saturday i had a couple spare hours to get on, not having yet moved the tool box in i struggled using random tools but managed to get some stuff done, got the front bumper off, it was corroded on had to use a lever bar and a hammer!!

Got the inlet manifold and exhaust manifold off and most of the front end

 

 

haven't got an engine crane yet and everything is coming off from the shell anyway so i have un done the front strut tops, and started to loosen the subframe bolts

[johniban 59 1 Cars]

as i still hadn't managed to get hold of an engine crane i used my head, with a bit of steel bar and a strop i wrapped it around the engine and tied a simple knot on the front cross memember, and lowered the engine slowly to the floor, was suprising easy even on my own! just kept slowly loosening the knot.

 

 

managed to snap a bolt in the subframe not sure how im going to get this out, its the last bolt holding the subrame on, possiblt have to buy some drill bits and drill it out

 

[johniban 59 1 Cars]

Then this little gem popped up on gumtree, advertised for £80 with a creeping ram

Found out it was just round the corner and managed to get it for £50

Its a make ive not heard of but its a 2 ton and i think mosts of them are the same anyway

 

 

ive already got the ram of and stripped it down, cant see any rear problems with it, going to try find out if i can get a seal kit for it

[johniban 59 1 Cars]

got my self a decent welding helmet from weldquip, its an swp, seems to be good so far, much nicer than the crap one i got from ebay ages ago that gave me sunburn around my eyes! not good.

 

Then made this...

 

 

For the body to sit on so i can safely repair the underside and work at a comfortable hieght around the car,

ill be adding castors to it at a later date and tie down fixings for when i need to move the shell to a body shop

[johniban 59 1 Cars]

got the body on the table last night

 

 

then done a little bit of work on this

[johniban 59 1 Cars]

Over the weekend i managed to repair the drivers footwell rust at the rear,

doesnt look anything pretty but its nice and strong at there is no rust witch is good, i do need to work on my metal shaping skills tho!

 

 

I didnt want to smooth any welds down as i didnt see the point i wanted it to stay strong.

 

[johniban 59 1 Cars]

Then i cleaned up the offside chassis leg, ground down all the rust, i will use filler at some stage to get it nice and smooth

[johniban 59 1 Cars]

Then i set about trying to rebuild to offside sill, its pretty hard considering there wasnt anything there as it had completely rotted away! so trying to copy the other side,

i stopped after a while as i think i need to get some thicker steel. i think the steel im using is thoo thin for sills

[johniban 59 1 Cars]

last night i managed to start on the front end, removing parts that were in the way or wont be used any more like the brake lines and fuel lines and brackets, gave the old paint a clean up as i want to try and keep most of it, and managed to remove a snapped bolt for the subframe with an angle grinder

 

 

I then set about wire brushing (with angle grinder attachment, all loose rusty paint, im quite happy to remove the surface rust and keep the surface as it is, i dont see the point in chopping out the pitted areas as they are strong still, so i etch primered and stone chipped

 

[johniban 59 1 Cars]

last night i got on with what i was dreading, the off side rear sill, purchased a repair panel and cut from it what i needed it was only the cover sill,

i then had to guess and make up panels for the inner sill as it had all rotted away,

made all panels from 1mm steel so nice and strong, forgot to take pics at that point, but i welded it all up sorayed some etch primer and prepared to fit the cover sill.

[johniban 59 1 Cars]

Rubbish picture, the light in the garage isnt up to much, i have to hold a torch in one hand while im welding so i can see where im pointing the gun!

 

Got the cover tacked on, i just need to sand down the edges and smooth it into the old sill, and then i can build up the inner arch next to the sill

[johniban 59 1 Cars]

Then got bored at work and made myself a new number plate for the daily, probly a tad illigal but weel see

[johniban 59 1 Cars]

all rust repaired and fillerd before paint

 

[johniban 59 1 Cars]

strengthened the rusty tow eye with 2mm plate

 

then started on the underside, used the crane to pull it on its side

 

 

[johniban 59 1 Cars]

Lots of room in the garage now

 

 

tried to copy the other side as much as i could but as there wasnt any metal here to copy from i just tried my best

[johniban 59 1 Cars]

havnt got any more pics of the rest of the inner sill rebuild but i sealed the seams and stone chipped the whole underside

then sanded and stone chipped the outer sill

 

refitted fuel tank

 

 

repaired sub frame and fitted

 

rear axle back on for now and got it back the right way up

[johniban 59 1 Cars]

painting the wings

 

sadly i only used rattle cans as ive not got the compressor going again recently

 

front panel back on

 

 

looking at the under dash wiring.. what is this for?

[johniban 59 1 Cars]

Removing the 1.9 engine loom from the car

 

Picked up this local to me, an uknown millage xasara vts engine,

[johniban 59 1 Cars]

 

Quick test fit

[johniban 59 1 Cars]

New engine bay stickers

 

 

Now as im going to be using carbs... i know everyone will say use throttle bodies, but as i dont have stupidly loads of money to keep getting the car mapped, and i like old schoolnes of carbs

 

i got myself a dizzy conversion kit witch replaced the vacuum pump.

 

ditch all of this!

[johniban 59 1 Cars]

im going to be putting the battery in the boot, not for weight distribution ect but just to clean up the bay a bit, as the old mount is bulky and looks crap i made my own.

 

 

fitting ignition module and wiring up

 

couple of pics i missed earlier

 

[welshpug 1,661]

you only need one mapping session, whereas with carbs they need maintenance and servicing, and you never get as much power or torque or a good powerband.

 

not to mention fuel usage.

 

you don't have to get your 106 mapped very few months do you? so why should you with a throttlebody setup on your 205?