Shell Strengthening/seam Welding

[Kane 34]

In the coming months I'll be making a start at stripping down the 205 to begin a proper restoration as originally intended. This will involve a full respray inside and out including removal of all glass, obviously following any body repairs required.

 

Since the shell is going to be in a position where access will not be a problem i thought it best to carry out all strengthening works possible. The intention for the car is primarily road based and the aim is to end up with a relatively stock looking 205 so no roll cages here.

 

Following some searching it seems the opinion is slightly divided on seam welding a shell when not using a cage. However, I reckon any additional strengthening is only going to be beneficial, even if it proves to be a nightmare with seam sealer etc. What's peoples experiences here?

 

Next up, what other shell strengthening mods are recommended for this sort of application? Is it worth beefing up strut towers or does doming only become an issue with more harsh uses? What about the firewall by the pedal box, overkill on a road car? And any others that spring to mind?

[TAG 25 1 Cars]

Personally I wouldn't bother if it's just a road car.

 

As I understand it, the PTS cars were not stitch welded, only strengthened in a few areas (top mounts, subframe mounts, beam mounts)

[allanallen 528 2 Cars]

Strengthening to the seat mounts and pedal box area would be worthwhile, possibly the strut tops too but this would obviously be visible unless you could do it from underneath.

[Kane 34]

I wouldn't be worried about modifying the strut tops as its hidden 99% of the time anyways. I'll add seat mounts to the list as well.

 

The front subframe will be getting stitch welded also, I hear this is extremely worth while considering the minimal cost.

[Tom Fenton 1,541]

For a road car I don't see the point of doing anything. Your time better spent on rust treatment and prevention in my opinion.

[Malc 45]

following on from this, if a track based car what would the best options be? Im planning to add strenght to subframe, top mounts, bulkhead, top engine mount and pedal box, anything im missing? possibly floor pan/sill both sides?

[Tom Fenton 1,541]

I'd only do a lot of this stuff to a true rally car, eg that will be used hard on rough terrain.

 

For a circuit car it's worth doing the pedal box mount, especially if it's using a non-servo pedal box arrangement.

After that remember extra weight is effectively the same as less power.

Spend the time doing a good job of the cage, tying it into the pillars is worthwhile and noticeably stiffens the car.

[GLPoomobile 958]

What about the handbrake area? I've seen the metal in the floor split there on a few (inc one of mine). Might be worth adding some plate just for future peace of mind, as it might look fine now and then fail in the near future.