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Default 19th March 2017, 05:58 PM

Completed the drivers side rear arch everything back together with a generous coating of Dynax UC cavity wax.

Started on the passenger side rear arch, all the rust spots marked out. (Spot welds, captive nuts and seams)

Ground back (Dremel then decided to burn the motor out) and zinc rich primer applied.

Seam sealer and then Stonechip coating applied


Top coat applied and left to dry before putting everything back and applying cavity wax

This is what started all this off, the battery box, lots of surface rust on the seams, ground back, primed with zinc rich paint and then a lot of seam sealer applied and left to dry for next weekend.


This was during the grinding


I then thought bollocks I may as well sort out the area behind the crash beam.
Rust spots sanded away

The whole area was then cleaned and keyed and masked up, ready for seam sealer and zinc rich primer.

Fully coated in stonechip

Top coat and clear coat

Back together waiting for the crash beam to dry, yes I've cleaned that up and painted it also. I will also need to cover the drivers side box section, where the duct tape was hanging off, sprayed cavity wax in the exposed box sections. I replaced the rusted and rotten fixing screws (Cotswold mini quick delivery)
  
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Default 13th April 2017, 12:45 PM

Battery box being painted (the run is no longer there)


Trailing arm and coil over removed



What I had to contend with next to the fuel tank?



Cleaned and ground back, very awkward to get to thankfully the Dremel (new one) can get in there


Zinc primer, Seam sealer, stone chip and then top coat applied




Not surprisingly the wheel bearing was not in the best condition

Old v New

I'm trying to keep as many of the original bolts as possible, although rust has eaten a few, sanded back, zinc primer, paint and then laquer, ran them all through the appropriate die to clean up the threads.


Anti roll bar removed ready for the flap disc on the grinder


Back to bare metal


Repainted and lacquered


RARB Brackets repainted in Por15



Brake caliper carrier restored, all rust and contamination removed, primed, painted and lacquered in VHT paint



Subframe and trailing arms now being sandblasted ready for collection next week (these are donor items and are in better condition than my own)


The reason I am having to do this now. 15 years and counting

  
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Default 13th April 2017, 11:31 PM

Fantastic car and great choice of wheels. That's some work you're putting into it. Exactly the colour I'd get.
May I join the list of people who want it should you ever decide to sell.

Oh, what did you think of the Toyos? Thinking of replacing the RFTs on Ms 16v's Cooper with them.

Last edited by SlimJim16v; 13th April 2017 at 11:36 PM.
  
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Default 14th April 2017, 06:46 PM

excellent work so far!
  
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Default 16th April 2017, 06:59 AM

After far too much gentle persuasion and thinking I removed the brake caliper, the hand brake cable would not could come out, so I resorted to drastic measures.

Finished off with a hack saw

It appears that on my very early model the cable attachment was different? It had what looked like a complete bush all the way through with a flange at the top. Which was removed with a grinder on the Dremel, a HSS Drill bit, two broken flat headed screw driver tips (It was welded in place with rust), but succumbed to a hammer and chisel in the end.

Old


New


Caliper being prepared for paint


Being painted with VHT paint



Coilover all cleaned up, with the top mount repainted
  
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Default 20th April 2017, 08:56 PM

Calipers being progressed.

Handbrake cable fighting continued on the drivers side, grinding, drilling, heating and much hammering the connection came out.
During the fight

Cleaned up afterwards


Before and after together


Passenger side completed - nice and glossy, I have new springs to install when all the paint has hardened
  
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Default 29th April 2017, 10:00 AM

Items back from being shot blasted, they still required work with the flap disc on the grinder and grind stones on the Dremel


Treated with Bilthammer hydrate 80, Coated with lots of Bilthammer Electrox zinc primer and then painted with Por15, then clear coated.



Brake disc bell housing painted


Sub assembly begins on passenger side after 5 days of the paint hardening, I got bored with grinding and rust all bolts torqued and anti seize compound used on mating parts.



Trailing arm bracket painted and then assembled with existing powerflex bushes and probably far too much silicon grease


Drivers side had to be removed as a complete assembly as I could not get any of the wheel bearing or caliper carrier bolts out. Lots of heat a rather large breaker bar on the work bench sorted that.



Control arms ready for assembly with powerflex bushes


Sub frame after work with the grinder and Dremel, which will then be treated with zinc primer, painted with Por15 top coat and then clear coat.


This weekend hopefully with be

Subframe painted
Removal of stupid plasticine brake disc retaining bolt on the drivers side, which is part way drilled out
Drivers side trailing arm attacked by the grinder after being shot blasted
Control arm powerflex bushes to be installed
Drop links repainted
  
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Default 29th April 2017, 10:01 AM

Bank holiday weekend work was limited

Control arms with the powerflex bushes installed with a copious amount of silicone grease


Subframe and drivers side trailing arm treated with Bilthammer hydrate 80, doing it's magic of converting the unable to reach places within the pitting on the surface.



The sub frame was then primed with zinc rich paint and painted with Por15 top coat, after which I realised that I had encountered a setback that has cost me a great deal of time and effort, as the donor subframe I had purchased (it was advertised for an R53) was incorrect as it did not have the brackets for the anti roll bar.



Drop links before and during, I am trying something at the moment that I have read delivers good results with respect to surface corrosion, rusty bolts and the drop links are submerged in malt vinegar.


Drivers side brake disc and calliper carrier cleaned up and painted



The repaired, cleaned up and new parts are building up ready for the reassembly.


Last edited by RT2002MCS; 1st May 2017 at 06:30 PM.
  
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Default 15th May 2017, 06:10 PM

Hard brake lines were never going to be removed easily, so after a week of soaking in fluid I gave up, I even bought a set of flared spanners still no use at all so I cut them off.


So took the opportunity to purchase a set of Hel braided brake lines in black.

Which means I have had to buy a flaring tool, I'm quite pleased with my practice results this week.


I have finally got the rear subframe off after a lot of wiggling, I was unable to remove the rusted in control arms when on the car, they needed to be in the vice with a vey long breaker bar.

It's getting a little cluttered in here now, I have also received a replacement subframe and full refund after my original purchase.

This is what I am left with to clean up to bare metal and prime, stone chip, topcoat and cavity wax. Oh joy.







Got the drivers side trailing arm ground back to bare metal with a flap disc and then painted.


Battery box now completed with all the heat shields removed
  
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Default 19th May 2017, 05:30 PM

the car looks the nuts!!

Can't wait for the next update!


  
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