grim_d
Unlikeable idiot.
- Messages
- 4,220
- Location
- Scotland - Ayrshire
Hello all,
I have been working on this project for a while now, but now that I am actually at the welding stage it's high about time I put a project thread up.
Progress has been slow due to losing my job last year and having wrist surgery at the start of the year which I am having to have repeated in 3 weeks, so that's another 3 months not being able to do anything, but I will update as and when I can.
For those even more interested there are more photos in my albums.
In December of 2009, after 5 years of 1.4 Sunny ownership I acquired "wee P", a 1992 Nissan Pulsar Gti-R, for those who don't know they are 2.0 Turbo AWD, most people think they are ugly, they are, but I adore them.
I bombed around in it for about 4 months loving (almost) every minute of it then this happened, a lorry cut it a bit fine and snagged the front of it, minor cosmetic damage, I was still gutted though.
So I bodged it back together with cable ties and continued to bomb around in it for a few more months, then I got a lockup, and the restoration started.
First things first, popped the engine out,
Then stripped it to a bare shell...
This gave me a good chance to assess all the areas requiring attention,
Crumpled floor rails/ARB mount, these are supposed to be completely straight, likely due to incorrect use of a jack, I should also mention the outer skin of the ARB mount was rotten so ideally these needed replacing anyway.
N/S sill, not sure what has happened here as it is an unusual place for these to go in, perhaps unrepaired damage from long ago.
O/S sill, small hole
N/S and O/S Rear arches, very common areas of rust, every one of these cars not fully sealed will go here.
O/S and N/S rear footwell, more about these later.
So now work could begin, but I wasn't going to scrabble around on the floor working on the underside, so with the help of a few mates we rolled the shell onto its side, but not without giving it a comfy seat first.
First up was to remove all the underseal and then get the O/S floor rail removed for repairs.
You can see here just how knackered the old ones were, pictured next to a genuine Nissan replacement rail, thankfully the rear section of the rails were fine so they will be re-used
Here is just how bent the floor is because of the damaged rails
So with all the underseal removed and a quick wire wheel over everything the true extent of the work required was revealed, all in all, not too bad!
The other floor rail has been left on for alignment purposes, if the rails are not in exactly the right place the the front ARB will not be able to be bolted back on. The plan is to mount the ARB and weld the new rail on then repeat for the other rail.
So.. I started tackling the rear floor, everything between the chassis rails. Lots of wire wheeling and Bilt Hamber deox gel.
This is one of the rear subframe mounts and thankfully the only one that requires attention, a little rot on the outer skin requiring a patch panel, yet to be made.
This brings us up to tonight, remember the floor rot I touched on earlier, well here it is from the outside,
Now obviously I cant tackle these areas until the rails were removed, so the O/S repairs happened tonight.
Rot Removed
Plate Welded in
dressed and etch primer, notice some of the plate has been removed near the sill, was unhappy with the welding, porosity probably caused by contamination, this will be repaired at the same time as the sill.
So that brings it up to date, C&C welcome and hope you enjoy the read.
I have been working on this project for a while now, but now that I am actually at the welding stage it's high about time I put a project thread up.
Progress has been slow due to losing my job last year and having wrist surgery at the start of the year which I am having to have repeated in 3 weeks, so that's another 3 months not being able to do anything, but I will update as and when I can.
For those even more interested there are more photos in my albums.
In December of 2009, after 5 years of 1.4 Sunny ownership I acquired "wee P", a 1992 Nissan Pulsar Gti-R, for those who don't know they are 2.0 Turbo AWD, most people think they are ugly, they are, but I adore them.
I bombed around in it for about 4 months loving (almost) every minute of it then this happened, a lorry cut it a bit fine and snagged the front of it, minor cosmetic damage, I was still gutted though.
So I bodged it back together with cable ties and continued to bomb around in it for a few more months, then I got a lockup, and the restoration started.
First things first, popped the engine out,
Then stripped it to a bare shell...
This gave me a good chance to assess all the areas requiring attention,
Crumpled floor rails/ARB mount, these are supposed to be completely straight, likely due to incorrect use of a jack, I should also mention the outer skin of the ARB mount was rotten so ideally these needed replacing anyway.
N/S sill, not sure what has happened here as it is an unusual place for these to go in, perhaps unrepaired damage from long ago.
O/S sill, small hole
N/S and O/S Rear arches, very common areas of rust, every one of these cars not fully sealed will go here.
O/S and N/S rear footwell, more about these later.
So now work could begin, but I wasn't going to scrabble around on the floor working on the underside, so with the help of a few mates we rolled the shell onto its side, but not without giving it a comfy seat first.
First up was to remove all the underseal and then get the O/S floor rail removed for repairs.
You can see here just how knackered the old ones were, pictured next to a genuine Nissan replacement rail, thankfully the rear section of the rails were fine so they will be re-used
Here is just how bent the floor is because of the damaged rails
So with all the underseal removed and a quick wire wheel over everything the true extent of the work required was revealed, all in all, not too bad!
The other floor rail has been left on for alignment purposes, if the rails are not in exactly the right place the the front ARB will not be able to be bolted back on. The plan is to mount the ARB and weld the new rail on then repeat for the other rail.
So.. I started tackling the rear floor, everything between the chassis rails. Lots of wire wheeling and Bilt Hamber deox gel.
This is one of the rear subframe mounts and thankfully the only one that requires attention, a little rot on the outer skin requiring a patch panel, yet to be made.
This brings us up to tonight, remember the floor rot I touched on earlier, well here it is from the outside,
Now obviously I cant tackle these areas until the rails were removed, so the O/S repairs happened tonight.
Rot Removed
Plate Welded in
dressed and etch primer, notice some of the plate has been removed near the sill, was unhappy with the welding, porosity probably caused by contamination, this will be repaired at the same time as the sill.
So that brings it up to date, C&C welcome and hope you enjoy the read.