[car_restoration] Sorrento Gti16v Full Rebuild

[de Noir 0]

Now, split seam on b-post-sill outer joint solution. Decided not to do any plug welds, but to pull an extensive seam weld (created from many stitch-welds) from inside the cabin out, extending approx 7-10cms in rear quarter-sill joint.

To prevent panels from flexing, first were done few small stitch-welds, left to cool down completely. Process was repeated until complete planned weld length and position were covered.

 

First, panel joint was locally sandblasted and panel sealant was picked out (courtesy of mr.screwdriver).

I'm missing a photo of rough weld itself at the moment, will be added later.

Photos show mate doing detailing, finished weld and zinc-primer coating.

 

 

In quest for more stiffness here I thought of filling the sills with 2k automotive polyurethane foam, but when realized that filling the sill would prevent water drainage from inside rear quarter panel, I gave up.

At least until I figure out how to solve the drainage problem.

Edited January 3, 2008 by MH_

[de Noir 0]

The rear underside. Shell went off the trolleys to a regular mechanic workshop jack.

Closer inspection, cleaning, sandblasting and brushing revelaed unexpected...

Hole in the sill structure was most unpleasant surprise.

 

Note how and where the underside is attacked by rust:

- panel-nut joints

- panel joints (beneath panel sealer)

 

This particular hole started its life as rust spot at corner panel joint-bend, pictured above.

Taken its time, rust point has developed itself to a hole. Almost all happened beneath the sealer.

Metal plate was welded in, just the way it was done with the bulkhead hole.

 

Time spent on a jack was used to further inspect the shell from different angles and brush+protect spotted rust.

Instead of planned 2-3 afternoons, whole job done and described here took over a week, as with every move more rust spots were found.

 

Tar-based undersirde protection wasn't taken off where in healthy condition.

Edited December 19, 2007 by MH_

[de Noir 0]

The shell was again mated with trolleys and transported to a body specialist on a warm autumn evening.

Below: Angry, hungry and tired but ultimately satisfied me.

 

 

Work continued few days later. First, front wings were taken off.

Right wing was original, but left one, I suppose, cheap replacement after minor accident.

 

Note the difference between factory made and protected 15yrs old metal and much newer replacement part.

Inner wing condition is good on both sides, factory panel sealer was in superb condition, tight and elastic.

To preserve panel factory sealant where possible, I decided not to change left headlight housing panel with new item. It would be smoothed, filled and painted over instead.

 

After so much time spent dissasembling and destroying the stuff...

 

Bodywork photo story

 

First, the most obvious, largest dents have been taken care of.

Dented metal was pulled or pushed from inside out where possible and then filler was applied.

After first smoothing, whole procedure is going to be repeated with more attention to detail.

These are only rough sketches of what is to be done, more pics will follow.

Edited January 3, 2008 by MH_

[j_turnell 137 3 Cars]

Looks awesome, and im glad my car provided inspiration I will hopefully be doing something very similar to mine soon!

[cybernck 402 1 Cars]

simply amazing! you're doing what i daydream for my 205 GTI .

 

and best of all, i'll get to see the car when it's done .

[Edp 67 3 Cars]

Top work, keep the pics coming!!

[Baz 421]

Thats an excellent project! Seriously a proper full rebuild! Top marks and respect for dedication and effort!!

 

Jealous!

[de Noir 0]

Looks awesome, and im glad my car provided inspiration I will hopefully be doing something very similar to mine soon!

 

 

I like your car a lot.

 

Me still have no clue should I go for original look with red stripes and badges, or for a bit toned down, with chrome bumper stripes and no badging, as you did.

I guess it would depend on available-from-new trim and I'll worry about that later.

Edited November 13, 2006 by MH_

[dommorton 0]

I'd say with that amount of work carried out it would be standard all the way for me.

[Last Legend 0]

I would agree with dommorton,keep it standard,there are so many 'chavved up' cars out there that seeing a nice clean original 205 GTI is a rarity,wont hurt the value either,unlike modding it.

[j_turnell 137 3 Cars]

Well i recon you should do what you want to do mate as its your car at the end of the day. Personally i like the subtle understated look of blank badges and chrome inserts, i dont think it looks chav though tbh...

[Alastairh 47]

Yeah i like what James has in the flesh.

 

But i think for my sorrento im building over the next month, im going to go standard look, but freshly painted paintguy style mouldings, and i'll buy some new un dented, not scabby red inserts.

 

Alastair

[AJC 0]

looks well

[DamirGTI 342]

respect mate ! very didactically , and great pictures - excellent job

 

good luck !!

[28CRAIG 2]

I like your car a lot.

 

Me still have no clue should I go for original look with red stripes and badges, or for a bit toned down, with chrome bumper stripes and no badging, as you did.

I guess it would depend on available-from-new trim and I'll worry about that later.

 

I think the chrome stripes look good on a sorrento. j turnell car looks very nice the red stripes looks more chav they dont go with the green

[Alastairh 47]

Hmm.

 

But just been searching ebay, and spotted this un known local mint Sorrento, which has inspired me

 

[cybernck 402 1 Cars]

you know how they say about sorrento - "isn't that black?" .

[de Noir 0]

I read somewhere, sorrento color has only few % of green, main component IS black.

[j_turnell 137 3 Cars]

you know how they say about sorrento - "isn't that black?" .

 

 

lol

[Paintguy 0]

I read somewhere, sorrento color has only few % of green, main component IS black.

I've mentioned that a couple of times on here. Around 90% black, a bit of green, and some white pearl to bring out the green when the sun shines

[de Noir 0]

I've mentioned that a couple of times on here. Around 90% black, a bit of green, and some white pearl to bring out the green when the sun shines

 

 

It was you, then. I thought so!

 

Bodyshop activities are well under way, respray is scheduled for next week.

Unfortunately, I haven't got camera with me yesterday.

Edited November 22, 2006 by MH_

[de Noir 0]

Update time.

 

Doors and bonnet off, all visible dents and few new found rust spots are being sorted.

Both front inner wings have been cleaned of old sealant and protected.

Visible sections under the wheelarches will be later sprayed sorrento green.

 

I did the whole engine bay rust treatment by myself.

It wasn't very difficult at all and even had fun doing it.

Edited December 19, 2007 by MH_

[de Noir 0]

Aluminium door protector-holding-nipples are rendered away, holes welded, protected from inside and outside and then smoothed.

These are obsolete now, as OE tin holding clips are not sourceable from new any more.

Door protectors will be held in their position with (3M or similar) double adhesive mounting tape instead.

 

Rear quarter has been sorted in similar fashion.

Side protecor nipples also cut off. Holes, markings and dents filled and sanded, sanded and sanded again...

Dents everywhere, really curvy structure found here!

 

Edited January 3, 2008 by MH_

[Irish Al 0]

Looking good. Mines is a 91 as well but far more rust than you have found on yours.

 

The whole rear section behind the black section on rear bumper has rusted away. Yours looks like new ???

 

Are you sure it spent most of its life in the country ??? :-)

 

Al

[Alastairh 47]

Looking great