Project #3...Oh no, not another Nissan Figaro!!!!!!

[Pigeon_Droppings2]

Been a long time since I got some garage time....lots going on in my life lately but that's a different story.

Took a few weeks but I've mostly got the engine back together. Still a few bits left to go on like the turbo heat shield. Plenty of new shiny bits like turbo and alternator.

 

[Pigeon_Droppings2]

Made a start on the passenger side inner arch. These always rot in the same place...it's double layered with a plastic cover over the top...designed to retain moisture I guess!

Will butt weld the top and left...floor join (inside the car) will be lapped to make life easier (not a lot of room under the dash).

Seems I haven't forgotten how to make a patch....lets hope the welding goes as well! There will be another layer over the top but this one needs putting in first.

 

[Pigeon_Droppings2]

Tacked the inner panel in place...I'll weld this from inside the car when I'm doing the floors as it'll be a lot easier. Went OK considering it's been quite a while....was worried I'd forget how to weld. Have to say my new 3m mask is the nuts...so clear.

Outer panel went in ok...the bit in the left wasn't happy...I think there was seam sealer in-between the panels or something.

Knocked the top of the welds off...once the inside is done I'll stone chip the arch.

 

[Pigeon_Droppings2]

Same again on the driver's side...so far this Figaro is rusted in all the same places as the previous one! I knocked the tops off the welds and then stuck some etch prime on there. Still have to weld up inside the car but will leave that for when I'm doing the floors.

 

[mtt.tr]

Well done Mr pigeon.

 

[Pigeon_Droppings2]

Worked on the door hinge plated today...they must spray them with sea water before bolting the doors on! Spotted a small hole (top right) and had to go digging. Used some weld thro primer...I really dislike that stuff but needs must.

Came out ok...bit of etch then doors back on (stop me losing the fittings!).

Passenger side is a lot worse so that'll be fun for me!

Gas is running a bit low...wonder how much prices have gone up! Am thinking of finally getting a bottle of argon so I can learn some tig welding....had the welder in the loft for 2+ years!

 

[Pigeon_Droppings2]

Got a bit more done today...this side was a lot worse. I usually use masking tape for these sorts of repairs to make up the patch. Had to cut the support on the left to get some access....decided to weld everything shut instead of replicating what was originally there (couple tacks!). I might do the drivers side the same before it gets painted.

All went ok...packed up the welder...cleaned up...then spotted I hadn't welded the wing support back on...that'll have to wait till next time!

Bottom hinge needed a small patch too of course.

 

[rtcosic]

Progressing nicely.

Good to see some actual welding content for a change too.

 

[minimutly]

So decided to pull the turbo air pipes. For some reason one was wrapped in electrical tape...strange as electrical tape works well for....errr....electrics...I'm not convinced it's a good choice for a turbo air pipe!! I imagine the torn inlet pipe would have really been messing up the running. I guess the loss of pressure might result in rich running...just a guess.

I looked up the turbo end float...it should be 0.1mm. let's just say I didn't need a dial gauge...the shaft has huge play plus the pipes were soaked in oil.

New turbos are £500+ .....I may have paid £1,000 too much for this car!!!

Decided to order a used unit...fingers crossed it works out. I happen to have seen the car it's coming from which was mint until someone crashed it - I met the guy when I was sourcing parts for Project #2....lucky he still had the turbo !!

I'll have to recheck the paperwork...I believe the car has had at least 2 new turbos so I'm thinking I really need to get down to the root cause of the failures otherwise the next one will just end up going the same way. I'll probably start by removing the water and air supplies and go from there....that braided hose is an upgraded turbo oil supply line so I'm thinking someone at least tried to do it properly as the oil supply line is a common failure point.

You paid for it?

 

[Pigeon_Droppings2]

You paid for it?

The market for these cars is a bit crazy....especially in the spring/summer months. I can't believe how much they rot...this was made in 1991....it isn't really that old and it's new enough to last better than it has I think. Those door hinges were just bolted straight onto the bare shell I think!

I'm trying to ignore the floors and the rear of the thing....quite depressing to look at!

 

[Pigeon_Droppings2]

Been working on the rear window this week...I've got 2 of them (the really rough one came off this car).

Got some bits done...this sort of stuff takes me an age. The rough one (first pic) is too far gone and beyond my tools...the less rough one (second pic) will have to be fixable. Fibreglass copies are available for around £350 but that's cheating and I'm not convinced they will fit the same!

 

[Pigeon_Droppings2]

Wish I had more metal shaping tools but we use what we have...had to make the repair in sections as the curves are pretty complex....so this took quite some time! The rear lip has a seal that fits over it...it was really difficult to get it shaped right as its a complex curve...I had to keep checking that the seal would fit!

Coated it in 1 part epoxy rust converter...I'll need to do a little filling but luckily the outside gets covered in canvas and the inside has a trim on it so quite forgiving.

Definitely out of gas after all that welding...I've ordered a new mig bottle and also a bottle of Argon. It would have been really useful I think doing the window repair using TIG...I'm planning on learning for the next one!

If anyone has any suggestions on useful tools I can buy for this sort of metal shaping please let me know....aside from hammers and dollies I have a metal folder and also a shrinker/stretcher.

 

[Pigeon_Droppings2]

Lots of filling, sanding,painting and I'm mostly ready for the canvas. The bottom weld joint is covered by a large rubber seal but I may stick some seam sealer on there...belt and braces. Also planning to wax the inside.

 

[Pigeon_Droppings2]

While I wait for rear the window canvas to arrive I've started to prep for repairing the sills. This is the brace I used for the last car I did...amazingly it all bolted in with no mods needed.

So either I have 2 straight cars...or two identically bent cars .

Bracing is a bit ott but as I already had it I just threw it in there. It cross braces using the door hinges and the seatbelt mounts so doesn't need any welding which I prefer. Does take up a bit of storage room so after this car is done I think I'll sell it to make myself some room.

 

[Pigeon_Droppings2]

Did the usual poke at the seam sealer on the sills...yup it's the usual rotten mess under there. The outer, inner support, inner sill and the floor are all rotten...so the only way to get in there and fix it is to cut it all off and work from the inside to the outside. The good news is we'll get to see lots of welding and metal bashing!!!!

 

[Pigeon_Droppings2]

Took me a while to get this sorted out...there was a good day of sorting out the fittings to the hubs.

It's only half way up...I'll leave it overnight and if it's still there in the morning I'll get it as high as I can. I'm thinking axle stands will be needed on the roll parts to secure it.

Its nicely built so pretty happy with it...wish I had this when I did the last car I can tell you!

 

[Spot the welders dog]

Some really good progress, rear window looks a treat. Just a tiny bit envious that you'll never again experience the joys of crawling off the floor with hot blobs looking for any way to penetrate a tender orifice.

 

[duncans]

great job there mate impressed

 

[Pigeon_Droppings2]

Managed to get the window canvas done yesterday (mostly)...came out pretty good. The canvas came with a cutout at the top!...makes alignment very difficult (I emailed the supplier to say delete that feature as all it does is make the canvas a lot more difficult to fit!). The bottom rubber seal still needs to be glued in...this window will actually be fitted to project #2 and then the one on project #2 will get a refurb and end up on this car.

I also got the sill cut out too but I didn't take pics yet so will get some over the weekend....its as bad as the project #2 car unfortunately.

 

[Pigeon_Droppings2]

This is where I got to today...stripped the remaining flammables off and covered the dash and loom with fire blanket.

Sitting on a seat working like this feels like cheating to me!

The wood prop isn't a prop....it's propped with a pair of axle stands...and the main mechanism used to raise it locks it in place. The wood is just there to give me a signal if anything were to move!

Got most of the sill opened up...if I have some time next week I will start on the floor repair. Going to be a lot of work but a lot easier than the last time I did this....so nice sitting and working with a cuppa within easy reach!