Bodywork repair

We manually cleaned external body panels and removed tar from the rusty bottom surfaces. At the same time engine components were prepared for precise measuring of the wear and tear.

We cleaned repairable structural components of the body in the sand blast camera and cut away unrepairable sections of the sheet metal.

Rear door frame had penetrating corrosion damages almost all around the opening.

Overlapping patches in the rear wheel arches forced replacing of the whole part.

Lower part of the side door pillar was destroyed by corrosion.

View from the front wheel arch on several layers of overlapping patches on the passenger compartment front wall.

Top of the front wheel arch required replacement panel.

First and 6-th cross members were damaged most seriously so we planned replacement.

We removed overlapping patches from the outside body panels achieving access for investigation of condition of the inner and outer doorsills.

Arrived first package of the sheet metal parts for recreation of the body.

We cleaned prepared for restoration all removable body components.

We self-manufactured new doorsills.

We cut away damaged sections of the front longerons. New sections of the front longerons were welded precisely in place.

Shelf of the engine compartment had corrosion damages penetrating through body of the shelf and reinforcement plate nearby attachment points of the fuel tank.

We plugged holes in the body of the engine compartment shelf and welded-over new reinforcement plate.

Rear longerons were improperly repaired so we had to replace whole structure.

We self-manufactured replacement profiles for substitution of the damaged rear longerons.

Prepared sections were attached to the framework of the body.

We separated overlapping patches from the base structure.

Now we got a piece of body to restore.

We welded together self-manufactured missing areas of the panel with remnants of the original wall.

We self-manufactured new channel for seal of engine compartment.

New sealing profile channels were welded to the restored engine compartment shelf body.

We continued work on body cutting away damaged bottom areas of the structure and tailoring new sills. We were working on recreation of surface coatings on various suitable for the further use engine, running gear, electrical and braking system component.

We self-manufactured replacement panels for the front wall of the passenger compartment.

We welded in place prepared new pieces of the door frame and outer shell.

For repair of the lower parts of the right side doorposts we completely removed front wheel arch.

We disassembled and after cleaning sent for galvanizing door check straps.

Parallel to the body restoration we were working on recreation of the surface coatings on various suitable for the further use components of the engine, running gear, electrical and braking systems.

We cut away damaged floor crossmember bars.

Longitudinal frame members had several damaged areas which we removed.

We self-manufactured substitution plates to recreate frame members.

We welded on new frame crossmembers.

We returned to the place new sills, reinforcement profiles and jack supports.

We re-created longitudinal frame members under the front row of seats.

We self-manufactured new cover plates for front parts of longitudinal frame members.

Welding on prepared parts we completed re-creation of the front section of the frame.

We attached to the partition wall restored lower sections on both sides.

Piping of the ventilation system was heavily damaged so we had to self-manufacture adequate copies.

Repaired pipes were sent for galvanizing.

We replaced whole network of the guide tubes located under the floor.

We welded in place new inner piece of the front panel, as well as lower ends of the front door pillars.

We prepared lower area of the side panels for welding of new patch panels.

We welded side patch panels and grinded seams.

Parallel to the body restoration we were working on recreation of the surface coatings on various suitable for the further use components of the engine, running gear, electrical and braking systems.

We recreated front doorsteps and outer shells of the front wings.

We welded into the position new panels of the front compartment floors.

We corrected shape of the new front panel section after welding.

Last step of the restoration was tin loading achieving smooth restored surface.

We cut out damaged sections of the door outer shells and produced precise patches for substitution.

We cut out damaged areas of the door frames to produce substitution patches.

As fresh metal was in the place, we grinded weld seams.

Lower section of the rear wall of the passenger compartment had countless penetrating corrosion cavities.

Preparing body for new floor we primed all restored framework components.

Welding into the place fuel tank shelve we recreated rear wall of the passenger compartment.

We welded in place new floor panels and afterwards grinded weld seams.

We precisely tailored and welded in place new doorsteps.

We tailored and placed in the dedicated position new panels of the engine compartment floor.

Most of edges around the door openings had severe penetrating corrosion damages.

We produced and welded into the place necessary profiles for recreation of the door openings.

Parallel to the body restoration we were working on recreation of the surface coatings on various suitable for the further use components of the engine, running gear, electrical and braking systems. Using prepared and delivered new parts we started assembling of the running gear components.

Joints between rear hatch posts and longeons were destroyed by corrosion so we had to recreate lost structure.

We welded in place rear floor panels and diagonal bracing to attach rear closing panel.

We precisely tailored and fixed in place rear bottom corner panels.

Welding in place all necessary parts we finished recreation of the rear corner junctions.

As all restored components of the body were assembled and adjusted, we removed bumper for repair of damaged items of the bumper’s structure.

We installed front bumper to make necessary compatibility adjustments.

Parallel to the restoration of the body we were working on recreation of the surface coatings on various suitable for the further use components of the engine, running gear, electrical and braking systems. Using prepared and delivered new parts we performed assembling of the running gear and transmission components.

We placed all necessary stainless steel guide tubes under the body.

We finished recreation of the passenger compartment welding together new doorsill and new floor panel.

We recreated heating system components placed in the passenger compartment.

We applied protective coating onto the bottom surface of the body before new reinforcement plates hided this area.

We welded in place new bottom reinforcement plates under the body.

We made all necessary adjustments to ensure even door gaps all around and started works on the precise shaping of the surface by soldering.

We recreated heating system piping under the body using new components.

We applied tin loading over restored area of the roof panel to achieve smooth and correct shape of the panel.

Before delivery of the body to the paint-shop, we checked whole surface of the body and marked noticed imperfections to correct.

After some hours of skilful handwork all flat surfaces again were flat, and round ones - round.

Restored body was ready for delivery to the paint-shop. Those who have tried know what is cost of this pure flat simplicity.

Parallel to the restoration of the body we were working on recreation of the surface coatings on various suitable for the further use components of the engine, running gear, electrical and braking systems. Using prepared and delivered new parts we performed assembling of the running gear and transmission components.

We continued preparation of the body for painting.

We applied final paint on the internal surfaces of the body.

We painted components in the period-specific colour.

Parallel to the restoration of the body we were working on recreation of the surface coatings on various suitable for the further use components of the engine, running gear, electrical and braking systems.

body 2