Disassembly, defects detection and compiling parts list
Initial condition and work order
Disassembly, defects detection and compiling parts list
Engine and engine auxiliaries repair
Running gear repair
Braking system repair
Electrical equipment repairs
Trim components repair
Other components repair
Assembling and final tests
Ventilation unit is demolished and replaced by air conditioner cooling radiator. Original air ducts are dismantled and replaced by soft plastic hoses led to widen by grinding radio opening on dashboard.
Wooden dashboard decorations are damaged by careless removing and installation of dashboard gauges. In some areas even veneer layer together with top varnish has been unripe. Completely separated segments had been simply glued in place with no restoration of warmish layer, but other damages were left as they are.
Front section of the floor (upper panel) has been rusted through in several places. To avoid sinking of the heel at the accelerator pedal there was riveted on aluminium plate, but missing lower attachment of the accelerator pedal to the floor has been valued as unnecessary luxury. It will be necessary to replace both levels of the floor panels in the front section.
Repairing bumper attachment after accident separated pieces of the bracket has been welded in wrong sequence thus preventing installation of the bumper in correct position. Right rear corner after accident has not been drawn out to the initial position for around 1 cm.
Rear gearbox support obviously has experienced some smash-up and its shape is far from original. Front propeller shaft unit is self-composed welding from two pieces of similar shafts. Seems it has not been balanced after welding.
Exhaust manifold has a crack - preferably it should be replaced. Exhaust system is self made and differs from original installation - whole system is welded together in one piece from the front till the rear. Repaired blown out areas are leaky again.
There are used adopted pressure sensors which required modification of wiring - wires are simply swaddled together. Self made modifications on the gearbox control junction - for some reason there are attached additional wires to original wire harness though some connections are left empty.
Under the dashboard instead of ventilation unit air conditioner heat exchanger is installed. Ventilation unit mechanism and controls are exterminated, partly adopted for use with later added conditioner unit. Air ducts composed from different size hoses simply showed together.
Wrong technical solution installing alternator led to destroyed alternator bearing and worn out attachment - flange on the alternator axle is rotating almost freely driving water pump just by accident. Original coupling unfortunately is lost.
All remaining components and parts are removed from the body and it goes to preparation for surface cleaning. First we put disassembled body on the rig to transport it to the cleaning station followed by welding work area.
We started rear axle disassembling first removing braking mechanism. Brake cylinders had been recently replaced, but other neat details of brake calipers like springs, pins and dust shields were destroyed. Brake pads were swished off and falling out of the calipers.
Disc braking mechanism of this model is attached to the axle through bushing. Bushing sealing rings and plastic inserts were worn out and grease was mixed with mud. Sliding surface of the bushing contrary part was damaged by rust.
Drive pinion had been experienced crash at some time in its life, but it had been a little serviced after that accident - someone had grinded sharp edges of both broken teeth. Separator ring of the bearing also was damaged. Teeth of the pinion had left clear footprints on the housing of the differential.
As self-fitted universal joint was not properly fixed on the generator axle, shaft outlet like a generator bearing was worn out. Such specific shim was used to adjust installation angle of the generator on the destroyed water pump and generator base plate.
Engine head had been recently serviced, but black depositions on the valves and pistons were signaling about problems with oil penetration into combustion chambers. Camshaft was in acceptable condition with no signs of excessive wear.
Crankshaft was removed from the engine so we could see scratches and excessive wear of the main and connecting rod bearing shells. Pistons were checked before decision to replace piston rings was taken. Like bearing shells also crankshaft main bearing journals and crankpins were worn out.
Body inside was covered with some tar hiding condition of the floor surface, but this hole at the accelerator pedal was obvious. A lot of debris was collected in the body cavities by the rear seat stimulating corrosion of the body from the inside. Poor restoration putting patches over the existing holes thus contributing even faster corrosion.
Those thick tar pads in the passenger compartment were also removed manually.
Under those carpets on both sides we found completely destroyed side walls - see cracks connecting all round holes and tracing to the outer edges of the panel.
As tar overlay was removed manually from the floor it become apparent that bottom flange of the front crossbeam was lost. Especially bad condition was noticed at the rearwards facing part of the crossbeam. Though also front faced structure of the crossbeam needed serious repair.
Rear wheel housings also underwent manual tar cleaning. Wheel housings had been several times repaired again and again welding over new layers of metal and filling gaps by filler. Now there was needed to remove all those kilograms of stone-like materials.
There was a fresh steel sheet put over the rear wing rusted area. It is generally wrong to put fresh steel sheet over rusty area - there were again bubbles under the paint on the rear wings along the bottom edge because of severe corrosion. More than 1 cm of filler on some areas of the rear wing did not help to stop destructive impact of corrosion.
Lower floor panels in the front part had been repaired and there were no visible rusted through cavities in this area. Unfortunately lower floor panels are welded to upper floor plates which were rusted through in almost each section - over the lower floor, behind it as well as behind crossmember. Rear part of lower front had been repaired at some time, but again it was severely damaged by corrosion so whole floor panels we had to replace.
Bottom part of the rear panel as well as rear longerons had severe corrosion damages. There were similar damages on both sides of the rear panel. Outer sheet of the rear panel was heavily corroded along the whole width and had rusted through areas in vicinity of exhaust outlet.
Body bottom and interior cleaning we started first removing unusually thick tar layer applied on the bottom surface from inside and outside. This layer was hiding a lot of careless repair traces. Holes in the rear inner wings in the area of rear window dimples were plugged by this tar. There were also hided holes on other surfaces of inner wings and floor pan in the same way.
There was discovered deep dint on the side of the body close to rearmost edge of right side window. This area has been repaired in the way requiring application of more than 1 cm of filler over this area. In the same area, but from the inside of the body, there was rusted through window sill area also requiring restoration.
Rear panel at the lower quarter was separated by rust across the whole width of the body. Around 1 cm of filler had been applied on the body sides between doors and rear wheel arches. Behind rear wheels layer of the filler on the body panels was of similar thickness.
Removable body components were completely cleaned manually. Rear edge of the trunk lid had been already repaired putting fresh metal straight over the rust. With no saying such solution did not lasted enough - there were again holes on the same area.
Body had been cleaned manually from tar on the bottom and inside, as well as paint over the external surfaces. As preparations were finished body was moved to the sand blasting camera for cleaning of repairable panels.
There were holes in the engine compartment around the firewall, front inner wing and front longeron junction. There were holes in the engine compartment along junction between firewall and inner wing.
We found rusted through holes on the firewall. Corrosion had been destroyed front panel and windscreen frame close to ventilation hatch. There were even rusted through holes on the inner panel under the dashboard.
There were cracks at all attachment holes of the crossbeam. Both profiles of the front crossbeam were not properly welded together. Old corroded part of previous part had been left underneath facilitating even faster corrosion of the structure.
Front longerons had been repaired putting fresh metal patches just over defects, leaving source of corrosion untouched. Three layers were removed to discover internal condition of structure. Similar situation was an opposite side of this junction - also several layers applied over each other.
All possible repair methods had been used on this car - gas welding, riveting and MIG welding had been applied here. Through holes in those panels water had been flooding into the doorsteps. This hole in the rear window dimple on the rear inner wing before was plugged by mixture of tar and filler.
There were rusted through holes at the junction of the rear longerons and doorsteps. Corroded were bodies of the longerons around braking arms attachment points. Overlaying longeron patches had to be removed to prevent further decomposition of the longerons. Damaged areas should be repaired in proper way replacing rusty places.
Rear part of the floor pan under the rear seats was completely destroyed. Handbrake cable brackets were repaired in wrong way and it was necessary to redo it as well. Trunk floor, trunk floor crossmember and longerons at the rear of the car were completely destroyed by rust.
It was needed to self-produce and replace rear longerons completely. It was not possible to restore rear panel - damages were too all-round. Close to silencer bracket like rear panel also trunk floor was rusted through.