Overview period - week 07, 2019.
1. Progress of the project.
We cut away all inevitably damaged components and performed initial cleaning of the carcass removing residuals of the protective resin and excess of rust manually.
We applied epoxy primer straight after shot blasting of the body carcass to prevent possible further corrosion of the cleaned surfaces.
We checked suitability of the removed sheet metal items for use as specimen producing replacement parts.
We manufactured new components to replace damaged items. New rear cross member again in place.
We attached new doorstep profiles and checked compatibility of the body carcass to already before restored chassis frame.
We re-shaped outer shell of the both doors stretching out deep dints on the door shell over the area, which is not accessible from the inside.
As structure of the carcass was recreated, we welded in place prepared patches of the door shells.
We installed restored doors to check the fit before further recreation of the carcass continues.
We started recreation of the carcass restoring salvageable components and using new elements to replace destroyed items.
Now we finished detection of the defects around the whole body carcass requiring welding. Cracks at the front panel – on both sides.
Front panel, at the joint with upper longitudinal member, both sides.
Diagonal member, at the A-pillar.
Joint between firewall and extension panel.
A-pillar, at the joint with firewall.
Rear wall, nearby joint with rear wheel arch.
In the centre, joint of the bar for hood lock installation and dash crossmember.
Joint between A-pillar and reinforcement plate for diagonal member, on both sides.
Connecting plate on the upper panel of the dash.
Firewall crossmember, on the both sides.
Front wheel arch brackets, on both sides.
Side plates of the front panel, both sides. We cleaned areas around noticed damages, performed welding and applied protective coat over repaired areas.
We adjusted even and sufficient gap between door panel and carcass of the A-pillar on both sides of the body.
We achieved even and sufficient gap between door edge and carcass of the B-pillar.
We fixed in place A-pillars installing self-tailored pieces of the structure.
We used remnants of the wheel arch structure to manufacture needed replacement patches.
We reconstructed inner part of rear wheel arches using remnants of previous construction as specimen.
We attached self fabricated outer flanges of the rear wheel arches and side plates at the rear of the carcass.
We welded in place prepared side floor pans of the luggage compartment. We applied weld seam mastic over all recreated seams.
Both sides required similar reconstruction activities.
We applied protective coating over reconstructed bottom area of the rear part.