[car_restoration] Sorrento Gti16v Full Rebuild

[de Noir 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

 

 

I'm fer sure. Service book and registration history show only two owners.

However, rear panel may look like new, but I found rust on many other spots, as pictures suggest.

Oh, and its back side wasn't this good looking either!

 

There's more photodocumentation but I see no need to detail virtually everything here, right?

 

I'm planning to show drivetrain, suspension, steering and brake details, as these attracted surprising amount of rust.

[Last Legend 0]

There's more photodocumentation but I see no need to detail virtually everything here, right?

 

I'm planning to show drivetrain, suspension, steering and brake details, as these attracted surprising amount of rust.

 

No,Keep em' coming,we all find it really intresting,I know when I did my engine/bay for my old show in my sig,digital cameras were'nt widespread then and I had to use a boring old 35mm,so didnt take that many shots,for those of us with an intrest please post the pics!

[de Noir 0]

Reinforcing seam weld on rear quarter-sill joint solution: Visible gap between the panels will be filled with panel sealer and sprayed over. Filler applied, everything neat and smooth.

 

Rear inside wheelarches treated with thin coat of stone-protector over the old one.

Old stuff wasn't taken off as it was in good shape, just thoroughly cleaned and jetwashed, surface brushed to get best possible grip for new coat.

 

Before respray, all panels get a coat of green coloured primer.

This has be done to prevent any possibility of gray colored primer getting visible through the paint.

Bonnet and tailgate off, windshield and rear glass out. Some rust found under, as usual.

 

Next step is assembling and aligning all panels to check gaps and then off she goes to full respray.

Edited December 19, 2007 by MH_

[j_turnell 137 3 Cars]

Looking very good keep us updated

[jOnO205 0]

just keeping doing what your doing because you are doing great!

 

keep make a song ^ hmmm

 

doing well fellow, im wanting to start one after xmas, this'l come in handy to learn!

[B1ack_Mi16 67]

Looking really good this, interesting to see how the rusty spots seem to be almost exactly the same as they were on my shell too. Maybe not that strange as they're both 205's, but anyway

 

Your rolling stand looks great, I never bothered making mine very professional like you did.

Should easily be modified so you can turn the car over on it's side too, that's handy when removing underbody rust.

 

But you're done with the rust threatment now I guess.

 

Looking forward to more pics.

[kikiturbo 0]

Looking really good this, interesting to see how the rusty spots seem to be almost exactly the same as they were on my shell too. Maybe not that strange as they're both 205's, but anyway

 

Your rolling stand looks great, I never bothered making mine very professional like you did.

Should easily be modified so you can turn the car over on it's side too, that's handy when removing underbody rust.

 

But you're done with the rust threatment now I guess.

 

Looking forward to more pics.

 

 

the stand was made in such a way so that side support could be added easily to turn the car on it's side..

when installed it looks like this.:

 

there is a diagonal support missing from the pic.. but you'll get the idea..

 

I can make some more pics of the stand as installed on my integrale if you'd like...

 

cheers

 

vlado

[Clarre 0]

Yes I want to see more of the stand.

 

I'm going to do some similar my self.

[de Noir 0]

Looking really good this, interesting to see how the rusty spots seem to be almost exactly the same as they were on my shell too. Maybe not that strange as they're both 205's, but anyway

 

Your rolling stand looks great, I never bothered making mine very professional like you did.

Should easily be modified so you can turn the car over on it's side too, that's handy when removing underbody rust.

 

But you're done with the rust threatment now I guess.

 

Looking forward to more pics.

 

 

Stand was done with thought to ensure sheer manuevreabilty of the shell without suspension and wheels on it.

It had and still has some design flaws, but so far proved itself very handy.

 

Luckily, underside had only couple of not-so-big rust zones, all of them located mostly in the rear, in tight corner where trunk underside folds and meets sill and rear quarter panel, as pictured earlier.

These were first done with sandblaster while car was on the trolley and detailed with steel brush on power tool (while having the shell on the workshop lift).

Rear underside welding was also done on the lift.

 

Messy job, really.

 

I thought of sandblasting the whole shell at the start, but after a tough debate some people here told me off.

Later, full sandblasting proved unnecessary, as everything was entirely doable with local sandblasting only.

 

I guess underside sandblasting is viable option only when you have to deal with big rusty areas, as your GTI belly side. I think you did just the right thing for your case.

Edited December 12, 2006 by MH_

[pug_ham 244 3 Cars]

Looking great, I wish I had somewhere I could undertake an indepth rebuild of such proportions on one of mine.

 

Then my 1988 white GTi would be back to fresh from the factory glory.

 

Maybe one day.

 

I was talking to someone a month or so ago that said they had a 30 x 10' garage / workshop that he doesn't use because access is tricky for daily use.

 

Its only a couple of streets away afaik so maybe I could move mine in there & start the work I keep putting off.

 

Graham.

[Dream Weaver 2]

Great project, keep up the good work

[de Noir 0]

Thanks...

 

Here are few details of the trolley. It's not tidiest design, but serves its purpose very well.

One day, when this is all over I will purify the design and draw workshop blueprints...

 

 

...which I did...

 

TROLLEY BLUEPRINTS

Edited March 31, 2008 by MH_

[Clarre 0]

Thanks for the picture of the trolley.

I have to go welding over the christmas.

[de Noir 0]

Thanks for the picture of the trolley.

I have to go welding over the christmas.

 

 

Cheers! Post the pictures!

Edited December 19, 2007 by MH_

[DamirGTI 342]

I'm interested in that trolley too

as i can see the throlley frame is made like original front (and rear) subframe designed too fit in mounting holes , but it will be easier to make it with some mesurments ...

 

cheers

[pugboyracer 3]

Superb thread, really enjoyed reading through it! I'm supposed to be working at the moment, but this was much more productive!

 

Looking foward to the next update!

[de Noir 0]

Superb thread, really enjoyed reading through it! I'm supposed to be working at the moment, but this was much more productive!

 

 

 

Just don't blame me when you get sacked.

[Clarre 0]

This is how I made my trolley.

And it works perfectly.

[de Noir 0]

Nice evolution. And nice garage, me likes wood.

 

Bigger castor wheels would be overall better choice for easier manuevering, but nevertheless this is very good.

[de Noir 0]

Monsieurs... She's back!

 

FULL RESPRAY

 

After two long months she's returned to my garage, neatly sorted and painted.

Now, assembly time, or at least I hope so!.

Edited January 3, 2008 by MH_

[welshpug 1,661]

laquered engine bay?

[de Noir 0]

laquered engine bay?

 

 

e v e r y t h i n g ! !

 

New engine bay "attention" stickers too!

[Richie 32]

Lookin' hot man.

[j_turnell 137 3 Cars]

Looks great! looking forward to seeing it gradually get put back together.

[Alastairh 47]

An appropiate smiley -