Kevinlincs
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Posts: 1609
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« Reply #195 on: 30 September, 2018, 10:01:59 PM » |
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As the replacement panel had been handily removed with more material than I really needed I could make the decision to join it to the bulkhead inside the car behind the dash rather than the windscreen flange itself. The A pillars I planned to stagger the joins rather than just jut straight through the whole pillar as that's not a very strong way to join it. The outer panel would be cut about half way up, the door section corner kept all original and the inner pillar would be cut a few inches from the bottom.
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Kevinlincs
Permanent resident
Posts: 1609
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« Reply #196 on: 30 September, 2018, 10:03:44 PM » |
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Measure, measure then measure again before cutting a big section of car away at this late stage!
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #197 on: 30 September, 2018, 10:05:46 PM » |
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Passenger side not too bad, clean up about all that was required..
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #198 on: 30 September, 2018, 10:06:28 PM » |
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Drivers side not so, but nothing too bad
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
Permanent resident
Posts: 1609
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« Reply #199 on: 30 September, 2018, 10:07:59 PM » |
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Well worth removing the original panel though, far worse underneath than even appeared on top!
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #200 on: 30 September, 2018, 10:09:37 PM » |
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Repairs made to the box section underneath then a new top laid on
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
Permanent resident
Posts: 1609
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« Reply #201 on: 30 September, 2018, 10:12:49 PM » |
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As you can see from this the "new" panel was in very good shape but even it had some rust around the little drain tubes from the 'screen corners
Note too how much has been remove from the donor panel, always best to use as little as you need
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
Permanent resident
Posts: 1609
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« Reply #202 on: 30 September, 2018, 10:15:17 PM » |
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My own opinion on those drain tubes is they create far more problems than they solve, every car I've now done that has had them has had issues around them, be that the AlfaSuds or anything else. So I cut the rot out, made up new sections and have welded them over.
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #203 on: 30 September, 2018, 10:16:50 PM » |
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Using the alignment frame to check things...
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #204 on: 30 September, 2018, 10:18:44 PM » |
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And using the body panels to check for bonnet and wing alignment...
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #205 on: 30 September, 2018, 10:20:48 PM » |
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Let the welding begin!
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #206 on: 30 September, 2018, 10:22:46 PM » |
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Plug welded to the bulkhead and overlapped on the inner A pillar, careful not to leave sharp edges for the sunroof drain tubes!
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #207 on: 30 September, 2018, 10:24:39 PM » |
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Repairs to the drivers side bulkhead..
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
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Posts: 1609
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« Reply #208 on: 30 September, 2018, 10:26:49 PM » |
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Grinding off takes an age
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Flavia 815 coupe Dedra turbo Delta integrale
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Kevinlincs
Permanent resident
Posts: 1609
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« Reply #209 on: 30 September, 2018, 10:28:31 PM » |
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Worth the effort though, outer pillar joint came out well both sides.
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