Hey guys, just thought I'd give you all an update on my rust hunting, metal cutting, new metal shaping, welding adventures on my series 3 ((Aus 84) (83-GLS-SE equiv)).

I've been busy recruiting my friends and their tools to help me in my quest. I've done heaps, yet f**k all compared to whats left or haven't found yet https://www.nopistons.com/forums/pub...O_DIR#>/11.gif but anyway, I thought I'd post a few pics. My ISP is having technical difficulties, so I'm going to attach them rather than link them. https://www.nopistons.com/forums/pub...DIR#>/wink.png

Here goes...

First couple are of one corner of the firewall.

the new bit tacked in a little

From under, this was an absolute bitch to shape.

Good luck man.

The roof section I had to cut out https://www.nopistons.com/forums/pub...O_DIR#>/11.gif https://www.nopistons.com/forums/pub...O_DIR#>/11.gif

Theres a factory weld along here that splits one piece of metal into two for the roof. On cold mornings, condensation sits along here and slowly rusts.

This is the piece I shaped and welded in, I'll just post the shaped bit sitting in the hole.

That new metal in the firewall are looks like a clean graft.Good luck.

This is the bit I replaced the air-con box holder piece with. This was the hardest thing to shape so far. I swear I musta been a blacksmith in a previous life to have got this flush.

This is one side of the rear wheel rust removal. Its stiched welded in. tack tack tack tack between tack between tack tack tack, etc I have to grind it down then fill in any bits i missed.

Nice welds.Remember to fill them after its done.

All of my new metal pieces and the surrounding old pieces get a coat of penetrol rust control spray, before being coated in galvanising spray. Then any exposed parts after that, get a coat of primer. If its an exterior part is is left for when I get a respray. If its interior it gets a coat of rust inhibitive paint or bitumen paint depending on where it is. Better safe than sorry. I dont want to have a new paint job f**ked by either not getting it all out, or not prepping the new metal properly. https://www.nopistons.com/forums/pub...DIR#>/cool.png

GREAT JOB!!

wow, i'm imperssed, you do good work and theres a ton of rust in that thing!



mike

If you can get it: Zero-Rust is the shizzit!

yeah its called california!



mike

Yup, as long as it's not a beach car. (Salty air and all that...)

Man I feel your pain with the wheel wells. I had to replace the both of mine on the 83. I just cut out all the rust that I could find then cut out the same piece from my parts car (that was rust free) and welded it in there. I know exactly what you mean by tack tack tack tack... I reinforced the wheel arch with a strip of 1" angle iron just to add a little extra strength to the area where the rear suspension mounts.

My 82 I'm getting is supposed to be rust free but every FB I have seen gets rust there.If theres some thier.I'll be welding it in with the new MIG I just bought saturday.Sinister 7 starts when the car gets dropped off.Then every H in there area shall be dead when it crawls out of my garage.muwahahaha.



Luis

Thanks everyone. https://www.nopistons.com/forums/pub...IR#>/bigok.gif

I wanted to do it right the first time if you know what I mean. Its a big job, but I'm only going to get heartache in the long run if I don't put in the effort now.

https://www.nopistons.com/forums/pub...IR#>/smile.png

yup, its better to fix it right once then to have to go back and fix it later



mike

^ no kidding, If i hear anyone say "fix it with fiberglass and bondo" one more time.....

A panelbeater guy that I used to know always said to never use fibreglass, cause it falls out. I found that someone had already put bog in some parts (roof section)..........

Hang on, I'll tell the whole story...

Ok, Im cutting the visible rust out of the top corner where its been previously bogged, with an angle grinder and figure ok, I can just weld up these small bits. So I start welding and the bog keeps catching on fire and burning. THis was really starting to piss me off, cos after every tack I had to lift my visor and blow the flame out. So, I decided, bugger this, I'm going to cut the bog out. Out comes the angle grinder (btw its really hard to use an angle grinder in the top corner cause of the seal lip and window frame) but anyway, here I m cuttin bog out and it falls out in one big chunk. I'm like . umm.. thats wierd....I look in to where the bog is and whammo, a **** load of rust all under there. Fu*k! So I think, well I'll just cut a bit out of the roof till the rust stops and then weld in a metal panel. This is when I find the factory weld along this line where the panel splits into 2 parts for the roof, and also where all the rust seems to be sitting. (Later I found out the reason - condensation on the inside of the roof runs down and sits on this weld) So I end up having to cut out about 9 inches of roof panel, all the way to the door. Arggh...what a mission. Lucky (I guess) I decided to cut the bog out or I would never have found it. Also funny thing is, the other side is perfectly fine. (I 'rust prevented' it nonetheless)



https://www.nopistons.com/forums/pub...DIR#>/wink.png

Wow, I just gut my 7 back from my brother. I'm going to start looking for rust.

I'm in California, but she's an outta state girl (federal emissions decal).

I hope she's from AZ or NM or TX.......

Got some more updates for you guys, I started working on replacing the boot. This would have to be the hardest thing I've ever had to shape with a hammer. Keep in mind this is 1mm steel as well. https://www.nopistons.com/forums/pub...IR#>/wacko.png

This is the piece by itsef. This was just the first piece I made, theres almost the whole boot still to go. https://www.nopistons.com/forums/pub...1047683358.gif

you may wanna just buy that panel new? fa01-70-750 if i'm not mistaken, its not expensive



mike

are you serious? Hell yeah, thats a heaps better idea. That would save me heaps of dicking around.

its the back part between the taillights and the hatch opening



mike

should I be looking under 81-83 parts or 84-85? I mean its an 84, but cos its Aus delivered, It might be more like the 81-83? wat do you reckon? Under 84-85 parts, I found "panel, rear end" PN: FA54-70-750



Under the 81-83 its PN: FA01-70-750C



Are they the same? Or which one should I go for?



Did you see my post under the "Wide body" thread about the sunroof parts? Any help on that would be much appreciated. https://www.nopistons.com/forums/pub...1047683827.gif

https://www.nopistons.com/forums/pub...IR#>/bigok.gif

as most opt to junk em..

kudos to your restoration..

I'll drink to that.https://www.nopistons.com/forums/pub...#>/biggrin.png https://www.nopistons.com/forums/pub...>/beerchug.gif https://www.nopistons.com/forums/pub...DIR#>/40oz.gif

https://www.nopistons.com/forums/pub...IR#>/blush.png

Thanks guys.

Its only you guys that keep me motivated to do this. I couldn't do it on my lonesome. https://www.nopistons.com/forums/pub...1047683827.gif

With me its a passion for these little monsters.The people keep a person motivated too but its a love affair myself.These things rule.Look at this for motivation.https://www.nopistons.com/forums/pub...#>/biggrin.png



Enjoy.

Printed and stuck on my wall. https://www.nopistons.com/forums/pub...IR#>/bigok.gif

Its funny, I've got a few pics of fb's and stuff on my wall in my office and people come in and theyre like "is that your family" https://www.nopistons.com/forums/pub...#>/biggrin.png

https://www.nopistons.com/forums/pub...1047683785.gif Yeah,I thought you might like that pic.I love the way its drawn.Too bad avatars are 100x100 and not like 300x300.My Avatar wouldn't be as blurred as it is.

i have no idea what the difference could be?!? the rule of thumb is to get the one for the right year



mike