Bodywork repair

 Preparing body for restoration dashboard was completely disassembled. Door pocket trimmings based on cardboard were damaged by humidity.

Headlight chromed trim rings were damaged. Decorative radiator grill was damaged as also was engine hood front nose – there were cracks around several attachment holes.

It was needed to disintegrate structure of the doors to get access to the door locks for maintenance. There were cracks in the door shell which we had to weld. Door strikers were worn out and we had to replace whole set.

There were discovered several cracks in the structure of the body requiring welding. Body was completely cleaned from any components before welding.

Body was separated from the frame. We attached body to the support rig used during cleaning and repair of the body.

Chassis was disassembled for defects detection. All rubber components were damaged and required replacement. As all components were dismounted we performed detailed inspection of the frame.

As external surfaces of the body were cleaned manually body was moved to the sand blasting camera for cleaning of the structural surfaces of the body.

Aluminium body panels – engine hood, luggage compartment hatch and both doors - were cleaned manually.

Bumper attachment holes in the body were asymmetric and we have to rework those.

Cracks on aluminium doors were welded during restoration course. Some most damaged door panels were replaced completely.

There were some carelessly repaired areas on the body which we had to machine additionally. At the areas with unsatisfactory quality we applied tin loading.

Body flange around passenger compartment was tin loaded along the whole length. Shape of rear wings was improved by tin loading.

Wings did not fit to the doors and it was needed to adjust shape of the bottom edge. To change shape of the front wings first we had to incorrect shape of the wing reinforcement plates.

After correction all body components were aligned in straight line.

We straightened damaged rear panels under the body. Damaged threaded plates were replaced.

Body supports at the front end had cracks. All cracks were welded and seams were grinded.

Fuel filler hatch was of incorrect shape and we made necessary corrections to achieve satisfactory fit.

Cracks on the aluminium bonnet were welded. It was necessary to correct shape of the bonnet since it did not fit to new radiator grille.

Broken cross members under luggage compartment were welded.

Asymmetric bumper attachment holes at the front were reworked.

New radiator grille was installed to test compatibility.

It appeared that front part of the body is smashed for some 3 cm.

Shape of the front part of the body was reconstructed.

It was needed to rework left side wing flange to achieve equal gap all around the engine hood.

As shape of the engine hood front part was reconstructed aluminium panels again were welded together.

Edges of the engine hood were precisely reconstructed metalliding aluminium layer to smooth out gap between wings and engine hood.

All recreated components were assembled together to check compatibility.

All body panels were prepared for painting in the sand blast camera.

Restored body and all components were sent to paintshop.

All surfaces of the body received specific treatment before painting.

First layer of the primer was applied.

Filler was grinded and applied repeatedly until required quality of the surfaces was achieved.

During the course of body preparation for painting compatibility of decoration parts and body was checked.

Prepared body was primed before painting.

Protective coat was applied over weld seams before painting.

Internal surfaces of the body were painted first.

All internal surfaces of the removed body elements were painted.

 Inner surfaces of the wings were sprayed by protective coating. Body areas which are forming wheel arches were coated by protective spray.

All external surfaces of the body and removed components received final coat of the paint.

Painted body was delivered to the workshop for assembling.

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