Disassembly, defects detection and compiling parts list

Car was delivered from storage to the workshop for disassembling. All received separated items stored in the car were unloaded.

First damaged bumpers were removed. All external chromed decorations were dismantled.

Door decorations and trimming items were removed.

All removable components like hood, doors and trunk lid were dismantled from the body prior to cleaning.

Whole ventilation unit was removed from the body. All dashboard items were taken apart.

All disassembled items were stored in the shelves until further detailed defects detection. All chromed decorations required re-plating. Some parts were damaged or improperly repaired so additional repair works were needed.

Paint from the body outside panels was cleaned manually.

Many poorly repaired areas were covered by thick layer of filler. Such thickness of more than 5 mm was unacceptable.

On the top section of the damaged doors was extremely thick layer of the filler.

Incurved after accident surface of the engine hood had been re-shaped also with thick layer of the filler.

After cleaning of the external panels body was completely disassembled removing both axles.

Before installation onto the welding rig for further treatment in sand blasting camera and following restoration works geometry of the body remnants was checked. Car still was having serious damages left after accident. In spite of the attached new front section of the front right longitudinal member its central part was left crinkly resulting right side of the car was 2 centimetres shorter comparing to left side. Correct geometry of the car chassis was reconstructed before further works were continued.

Dismantled chassis components were going to further detailed defect detection. Obviously left rear axle spring was broken. All rubber front axle suspension parts were damaged and scheduled for replacing. There was completely missing right hand wheel braking mechanism.

Body carcass was cleaned in the sand blasting camera.

After sandblasting there appeared some previously unseen damaged areas on the firewall. As expected rear wheel housings must be repaired again.

Left front quarter of the car after accident had been attached from another vehicle. Just in some places it was forgotten to weld together old and new components.

 
Repaired previously damaged areas of the firewall have rusted through. Replaced front longeron had not been protected and was rusted through.

Body in the area of front wheel housing on RHS was consisting of uncountable number of small patches.

On the left side front longeron profile and adjacent side panel have been repaired by overlay patch leaving corrosion source untouched. On the left side rusted through floor panels had been repaired simply welding patches over the rust.

On the RHS bottom part of the firewall still was not repaired after accident. On the LHS firewall reinforcement rib at the junction with wheel arch was damaged by corrosion.

Filler and paint were hiding damages of the front panel below windscreen and along the lower part of windscreen frame – this required additional welding job.

Some floor panels were stick together just by temporary welding spots. It was believed that rear panel under the seats already had been replaced, but in spite of that there was a rusted through hole in the centre along the weld seam.

Repairing right rear wheel arch all damaged unnecessary metal pieces were left with the body. Also on the left side corrosion source was left in the side hollow after the repair of rear wheel arch.

Sofftop drainage channel was rusted through to the both sides – water easily was penetrating into both - passenger and luggage compartments.

Central crossmember had not been repaired after accident – it was steel smashed.

Expecting bad condition of the car’s rear panel we ordered it new, but unfortunately it was not delivered – we received just bottom part of rear panel.

After cleaning it was obvious that rear lamp recesses must be reshaped to accommodate properly rear lamp housings. On the RHS additionally to mechanical damages we saw also corrosion penetrating through material on both – rear panel and rear wing edge. These complicated pieces we had to remanufacture manually since we did not receive expected complete rear panel.

Bottom part of the rear panel had a wrong shape, but we had patch panel to replace it.

Floor and longitudinal member in the front part of the car were not properly repaired after accident and first we additionally had to restore this structural area of the body.

Rusted through rearmost luggage compartment floor panel was cut away.

  
Floor reinforcement panels, which were believed already replaced, were cut away. It was strange to see so many mud and sand in these recently replaced cavity. On the opposite side even some other debris additionally to mud was discovered.

As floor panels were removed we took away damaged central crossmember.

Also in the doorsteps we found notable amount of mud magnifying corrosion. First left doorstep was removed completely.

For detailed defect detection and compiling required parts list we disassembled removed from the car front axle. It was mentioned already before that there was completely missing one of brake callipers. Shock absorbers were faulty in sorry state.

Steering arms may be reconditioned, but steering ball joints were worn out. Brake discs were worn out too much for machining before further use. One of threaded wishbone outside pins was bent and should be replaced for safety reasons.

 
Rear axle was completely disassembled for defects detection. Since one spring was broken there was needed another pair of rear springs. As brake drums were removed appeared that braking mechanisms are heavily rusted and brake linings had fallen off the brake shoes.

Condition of the grease in the main gear was signalling about poor maintenance – more precisely, no maintenance since long time ago. There was excessive play in the bearings, so it was needed to replace all of those. All suitable for restoration parts of the rear axle were prepared for further cleaning and painting.

Inspection of the handbrake revealed that cables must be replaced, but other existing parts would be restored.

 
After external washing of the gearbox we discovered that one of attachment flanges was broken – we had to repair it to save on parts. There was no clutch delivered with the car. Flexible propeller shaft joint was damaged.

Gearbox was completely disassembled for defects detection. First-second gear cluster was in poor condition – bearings and synchronizers were worn out.

Front brake calliper was completely disassembled for defects detection. Unfortunately it was needed to replace completely even this one unit since all parts inside the mechanism including all pistons were rusty.

Since braking system was left for a long time without braking fluid also rear braking cylinders were corroded in- and out-side. It was needed to replace whole units.

Main cylinder had been left with the residuals of the brake fluid inside, so corrosion of the all components was already started.

Propeller shaft was not bent and there were needed just new universal joints and rubber parts for restoration.

Components which appeared inoperable during engine tests were added to the required spare parts list:

Name	Table Nr-Position Nr	Part Nr	Qty.
Engine, fuel system, exhaust
Cover plate	01-33	1112500456	1
Pipe	02-60	1270100370	1
Seal ring	02-61	007603018100	2
Hose	02-63	6369970982	1
Hose	02-67	1270940491	1
auxiliary air cleaner	05-11	0000750632	1
Push rod	05-80	900331005051	1
Hex nut	05-81	000934005004	5
Hex nut	05-102	000934005010	3
Ball socket	05-82	0009910220	8
Pull rod	05-100	1270704075	1
Push rod	05-105	1270704375	1
Push rod	05-110	1270703275	1
Fuel hose	05-155	1279970782	1
Leak line	05-178	1270700035	1
Clamp	05-171	1272030235	1
Rubber pad	05-172	1279950057	2
Rubber pad	05-172	1279950357	2
Bracket	05-170	1272001040	1
Hex head screw	05-176	000961012047	1
Air filter element	06-04	0000945804	1
Air hose	06-15	1270940182	1
Rubber buffer	06-20	1890940085	3
Support for generator	08-26	1801551035	1
Clamping piece	08-32	1211550228	1
Tightening nut	08-33	1211550172	1
Tightening screw	08-31	1211551923	1
Collar screw	08-35	1211550071	1
Point unit	08-45	0001581690	1
Dust shield	08-46	0001580011	1
Distributor rotor	08-47	0001581531	1
Condenser	08-53	0001567101	1
Grommet	08-101	0009972281	6
Grommet	08-102	0001591585(0001590085)	6
Screw fitting	10-43	1279970572	1
Heating connection	10-45	1272001719	1
Thermostat	10-52	0012036975	1
V- belt water pump	10-85	007753009504	1
engine support rear	10-20	1112400402	1
Fuel pump	33-50	0010915201(0010911301)	1
Metal buffer	33-76	1169880511(1284780083)	3
Boot	33-43	1114710181	1
Filler cap	33-25	0004712030	1
Rubber guide	33-110	1804760384	9
Mounting clamp	33-105	1109950022	9
Mounting clamp	33-106	1539950120	1
Seal ring	34-04	1214920281(1214920180)	2
Exhaust pipe front	34-R2	1114903020	1
Pipe clamp	34-R31	1074920140(1114920240)	2
Exhaust pipe rear	34-R13	1114920904	1
Main muffler	34-16	1114912601	1
		1114912701	1
Rubber ring	34-36	1124920282	4
Rubber ring	34-33	1114920082	1
Rubber buffer	34-40	1129870140	2
Exhaust jacket	34-41	1114920614	1
Pad	35-06	1105020030	2
Cooling water hose	35-17	1105010282	1
Cooling water hose	35-24	1085010482(1115010382)	1
Clamp		900269045101	1
Bellows	10-27	1112240082	1
Pedals, propeller shaft, steering, brakes, servo
Clutch master cylinder	17-48	0002951406	1
Pad	17-08	1102910182	2
Screw	23-31	1119900020	4
lock plate	23-32	1119940209	4
Hex nut	23-33	304035010001(0009907751)	4
Check valve	29-40	0004313507(0004312807)	1
grommet	29-69	1869970681(1869970581)	2
Retaining spring	29-62	0004280373	2
Rubber guide	29-R82	1104200185	3
Mounting clamp	29-R83	2014280040(1104280041)	3
Bushings	31-29	1114620165	2
Grooved ball bearing	31-51	000625006004	1
Grommet	31-42	1119970081	1
Boot	31-44	1164620096(1114620596)	1
Switch	31-57	0015452124	1
Covering	31-58	1114620696	1
Knob	31-59	1105451037(1805450537)	1
V- belt power steering	32-148	007753012500	1
Filter	32-153	0002360055	1
Gasket	32-157	0002360080	1
Low pressure hose	32-170	0069970982(0039977782)	1
Electrical components
Support plate	37-03	1105410635	1
Battery	37-01	12V55AH	1
Mounting frame	37-02	1105400823	1
Clamping screw	37-04	1865410124	2
Super tone horn	37-140	0035421920	1
Super tone horn	37-140	0035422020	1
Ignition coil	37-150	0001580603	1
Hose	37-104	1215400159	1
Grommet	37-94	0009972681(0009972681)	1
Grommet	37-130	1109970381	1
Chrome ring	81-001	XXX	1
Glass	81-002	XXX	1
Chrome ring	100-001	XXX	1
Glass	100-002	XXX	1
Chrome ring	101-001	XXX	1
Glass	101-002	XXX	1
Windows
Windshield	60-01	1116715310 (1116715010)	1
Weather-strip	60-02	1116705639 (1116705439)	1
Garnish moulding	60-03	1116715030	1
Covering left	60-04	1116780137 (1116710136)	1
Covering right	60-04	1116780237 (1116710236)	1
Screw	60-06	1106710271	2
Covering	60-07	0009876657	1
Fastener	60-08	0009880981	8
Fastener	60-09	0009881081	8
Rubber seal	60-43	1156730224 (0009872656)	2
Rubber moulding	60-35	0009876657	2
Spacer washer	60-74	1087680113 (1107680013)	2
Window crank	60-72	1107600402	2
Window moulding	60-80	1116705737	1
Window moulding	60-80	1116705837	1
Spreader clip	60-82	0019883478	4
Fastener	60-87	0009881881	6
Fastener	60-88	0009881581	6
Covering
Weather-strip	61-18	1116835398	1
Weather-strip	61-20	1116805073	1
Cap	61-29	1116838036	2
Ledge left	61-30	1116830124	1
Cap	61-32	1118995008	2
Cap	61-33	1118995108	2
Expansion plug	61-35	1109870544	2
Expansion plug	61-36	1109870644	2
Expansion plug	61-41	1109870344