Disassembly, defects detection and compiling parts list

 

As doorstep trimming was removed it became obvious, that this body part has been kept together by rivets, screws and filler.

Separated parts of inner wings were kept together by screwed-on floor patch plate.

On both sides there were no anymore floor panels at the very front of legroom.

Also on the RHS front and central parts of the body were kept together by screwed-on floor patch plates.

As removed side windows appears that B-pillar on the RHS is almost separated by rust in two parts - only inner edge keeps top and bottom parts together.

There were rusted through holes in the area behind front wheels. Lower door hinge attachment brackets were also corrosion damaged. Though on the LHS these holes were hidden by several layers of screwed-on patch panels

Body was cleaned from residual debris as passenger compartment disassembling was finished.

Fuel tank was removed ensuring access to chassis components at the front of the car.

Luggage compartment was stripped down.

Front and central part of the body were cleaned from any insulation panels.

Luggage compartment lid hinges and locking mechanism were disassembled and examined. Usable components were cleaned by glass pellets and stored till painting.

Front hood had been several times broken and several times repaired by riveting on patch panels and welding on L-profiles on the RHS.On the LHS of the hood along the edge was welded-on piece of hot-rolled L-profile.

External surfaces of the body and components were cleaned in delicate manner - by hand. Internal and rust-damaged surfaces were cleaned by sand-blasting.

Front wings had been repaired by riveting on patches from the inside and bridging the gap of some 5 mm with filler. Similar has been repair of the front wing - here soft-drink can was riveted from underside.

Front end was covered with more than 5 mm filler layer as long as body metal was not properly and carefully enough repaired after accident. Rusted areas of the front panel in the front of reinforcement brackets were not repaired - brackets were just filled with filler to hide the defects.

Front end shape was not symmetrical after previous careless repair

Roof had not been before repaired and cleaning indicated damaged just some spots.

Rusted through holes in the luggage compartment - those were extensions of the cracks visible from the inside of the body separating front part of the car.

There was also similar hole on the front panel on RHS in front of reinforcement bracket just topped up by filler.

Rusted through holes at the rear edge of LHS B-pillar were before cleaning hidden by filler.There were rusted through areas at the bottom of RHS side window frame.

As expected before cleaning RHS B-pillar is almost broken - flimsy residual inner door-post fold keeps both parts together.

It has been more convenient to hide the defect of the RHS front wing by hammering-in damaged area and putting more filler with glass-fibre reinforcement layer.

Rear panel has also been heavily damaged and carelessly repaired.

Self-made battery box floor had no regular shape. Holes left after spotter tool application on the front panel had not been closed.

Shape of the jack attachment hole is achieved by application of sound insulation resin.

Engine compartment panels at the rear were separated by rust.

As all components accessible from the top were removed and car body manual cleaning finished we started to dismantle all running gear and power-plant elements.

There was severe oil leakage from transmission. All rubber parts must be replaced.
A couple of parts, like brake hose, seems had been recently replaced.

Exhaust system was not original for this model thoughit was still in working order.

Reinforcement profiles at the front of the body were also destroyed by rust.

There were missing part of the floor and the front diagonal reinforcement.

Self-made battery box floor was again rusted through. We started running gear disassembly removing steering gear and linkage.

Rear axle torsion bars were in acceptable condition, just bushings were worn out.

Power plant was removed together with transmission and rear axle.

Front suspension torsion bars were removed and wheel units dismantled.

Body was stripped down completely removing electrical harness and piping.

Most damaged areas were cut away before sand blasting providing better access to residual parts.

Sound and heat insulation in the engine bay was removed - area was prepared for sand blasting.

Components of pedal unit were falling apart and there was needed more detailed investigation, as for other dismantled components, to find out which parts could be used further.

At the front additionally to the floor pan there was missing part of central tunnel.  

Bare body was installed on the transportation jig which was used during sand blasting, welding and panting of the body.

Dismantled axles were completely disassembled and components assessed. All assembling units like braking mechanisms were knocked down to check condition of any part.

Gearbox was separated from the engine. Clutch was disassembled completely.   

Engine components were detached from the engine - carburetors with inlet manifolds were stored till detailed defects detection. Alternator and ventilator shroud were removed.

Exhaust system components were detached from the engine. Engine air cooling system devices were detached and disassembled.

 Front axle components were completely disassembled. All worn out components were put on the necessary parts list.

Steering gear was completely disassembled. All rubber components had cracks caused by aging and needed to be replaced. Steering gear had not been properly maintained and oil containing water had been damaged bearings and seals.

Alternator and starter motor were completely disassembled for inspection and repair. Bearings of the alternator and starter produced excessive play.

Motor was brought for disassembly. Thick layer of the deposits in the oil filter housing was signalling that engine had been working hard with limited maintenance.

Cylinders were cleaned from outside and inspected throughout. Working surface of the cylinders was worn out.

Feather on the oil pump drive shaft was damaged - edges experiencing load are crumbled off.

For unknown reason breather of one of the cam covers had been sawed away and plugged with some plastic foil. Most probably it is not available as spare part so another complete cam cover should be ordered.

There was a crack on heat dissipation rib of the head. Oil rings on the inlet valve stems had been lost elasticity and must be replaced. Grinding may extend life of existing valve seats.

Clutch presented acceptable overall condition - even driven disc was still usable. Clutch release bearing was worn out and must be replaced.

Fuel pump condition in general was acceptable, but all possible cavities were full with debris to clean out.

Carburettor assembly units were disassembled for cleaning and defects detection.

Main gear was disassembled and inspected.

 Gearbox was completely disassembled for inspection. Seals must be replaced as gearbox oil was leaking. Bearings of the gearbox were prepared to be replaced.

All powerplant supports were not anymore usable and must be replaced.