Restoration process


Overview period - week 51, 2018.

1. Progress of the project.

We welded prepared middle panels of the passenger compartment floor to the frame.

We welded in place fabricated outer panels of the passenger compartment floor serving as a base to attach doorsills, which are part of the body shell.

We checked compatibility of renovated frame and old passenger compartment floor to make necessary adjustments in drawings for fabrication of the new floor panel.

We produced exact copy of the rearmost crossmember of the frame.

We welded in place pre-assembled unit.

We fabricated new reinforcement ribs and applied protective coating over the surfaces of further closed cavities.

We prepared our copy of the luggage compartment floor for installation.

We finished recreation of the structure of the basic frame welding in place self-made replacements of the irreversibly damaged floor panels.

We finished recreation of the chassis frame and started restoration works of the body.

As welding of the frame was completed, we turned our attention to the body consisting of steel carcass and aluminium shell, which both were in sorry state.

We applied light sand blasting to remove loose corrosion products gaining access to surface of the remaining metal. Unfortunately, not much was left by enemy, which never sleeps. Because of corrosion holes along the whole surface, we planned to fabricate new doorsills on both sides.

Doorsills are made of several profiles welded together – even weld spots are broken.

At the front end, structure keeping together front and rear sections of the body was generally restorable. We should produce patches to restore broken and damaged by corrosion flanges adjacent to the floor.

At the rear part, new cross-member was required to keep both doorsills together again.

There was almost no metal of the rearmost body flange left. This element was keeping together rear part of the frame and rear of the body – we planned to fabricate new rearmost cross-member of the body.

At the rear bottom part, there was no aluminium of the shell left as well – we should cut away these spoiled sections and produce new patches to recreate these areas on both sides of the body.

Flange, which was fold around the steel carcass, was destroyed by corrosion, so we should cut away corroded areas and weld in place new material to recreate joint between aluminium shell and sheet metal carcass.

Sheet metal carcass had been repaired before, but again had penetrating corrosion damages over the whole surface – we had to cut this area away and fabricate adequate replacement.

Wheel wells had cracks here and there – we should try to weld all, if there is still left material to weld. Otherwise, we should fabricate completely new panels.

We had to replace all layers of the sheet metal carcass, which had penetrating corrosion damages.

Replacement flange had cracks and penetrating corrosion damages along the whole length. Since it was made carelessly, it did not keep together shell and carcass; consequently, we had to redo both – carcass and shell.

There were also cracks on other structural elements of the carcass – this was broken structure, which prevented rear of the car sloping down.

Broken L-profiles, which joined side and central parts of the body structure. Most probably, corrosion reduced the strength of given thin profiles. We should fabricate and install adequate replacements, as well as weld cracks of the panels where applicable.

We began works detaching all removable components left on the body – cover plates, door hinges, strikers, etc.

There was a lot of corrosion to fight with behind removed parts.

We detached rear section of the aluminium body shell.

Some sack of gravel was carried along with the car in the hidden cavities of the rear part.

Now we had access for recreation of the damaged junctions hidden behind aluminium shell.

As a next step, we detached front section of the aluminium body-shell.

Similar serious corrosion damages appeared on the elements of the front section of body carcass.

These longitudinal profiles in the upper front part were damaged in some accident and left unrepaired until now hidden by body shell.

Nearly any junction of carcass in the front part of the body was broken and insisted on repair.

We affixed mutual position of the elements and moved carcass from the frame to our rig for processing.

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