AE86 booter project

[Myles1970]

Speaking of welding panels, here's the leading edges of the rear wheelarches:



There's repair sections available at the moment:



.... but I'm thinking that I'd prefer to fab the small bit that I require...

And here's two strengthening gussets for between the front strut towers and the bulkhead...

 

[Myles1970]

great work Miles and inspiration to me.

Good, I'm glad..... I've wanted to do something like this since forever, but in the end I decided to just pull my finger out and get on with it

 

[Cosantoir]

Is that just normal primer you're putting non the car in the last pic of post 121?

 

[Myles1970]

Is that just normal primer you're putting non the car in the last pic of post 121?

it's a zinc primer...hopefully it'll serve to preserve until i'm happy with the metalwork from the windscreen forward. After that I'll key it and seal it with epoxy.

 

[Cosantoir]

Good shout will add it to the to the shopping basket

 

[Dcal]

Speaking of welding panels, here's the leading edges of the rear wheelarches:

View attachment 277082View attachment 277083

There's repair sections available at the moment:

View attachment 277088

.... but I'm thinking that I'd prefer to fab the small bit that I require... View attachment 277084

And here's two strengthening gussets for between the front strut towers and the bulkhead...

Those repair piece don't look that hot, I'm certain you will do a better job starting from scratch.

 

[Myles1970]

Good shout will add it to the to the shopping basket

yea, I'm sure you're aware that primer is porous, so this is for the short term while the shell is in the garage...I wouldn't risk it otherwise, even at that the garage is far from a perfect environment, but it's better than bare metal

 

[Myles1970]

Those repair piece don't look that hot, I'm certain you will do a better job starting from scratch.

no pressure eh?

I'm thinking that there's only a small repair required and that it'll be covered by the skirts and flares anyway

 

[Cosantoir]

at primer is porous, so this is for the short term while the shell is in the garage...I wouldn't risk it otherwise, even at that the garage is

I didn't actually but must be infinitely better than leaving bare metal showing like I admittedly have had to do.

 

[Dcal]

yea, I'm sure you're aware that primer is porous, so this is for the short term while the shell is in the garage...I wouldn't risk it otherwise, even at that the garage is far from a perfect environment, but it's better than bare metal

To be honest, I always use epoxy direct onto metal as I think it's the best chance you have of preventing problems later.
I'm not saying you are wrong, only why would you put a single pack product on first and a two pack later.
The adhesion will only ever be as good as the worst layer and my guess is it will be the zinc primer.
I tend to only use primers if they can be used as a one coat system (at a pinch) so epoxy or epoxy mastic.
I just mix up small batches by weight and spray or brush it on, just needs a clean and a quick flat when you want to overcoat it.

If I want a high zinc content I use Jotun Barrier 90 which is a two pack epoxy zinc primer.
It is cheap (compared to Galvafroid) at about £20 a litre, however it only comes in 10l packs which sort of spoils it for us diyers and it’s not as forgiving of prep as some epoxies and should only really be applier over sandblasted steel. (The same as Galvafroid or Zinga)

 

[Myles1970]

@Dcal yeah you're possibly right, but it's the way I've done it this time. Maybe I'm overly cautious about spraying 2k and wanted to do it in one shot, while not wanting to leave any metal bare until I'm ready to do that, and the front panel, bulkhead and front apron were partially bare when I bought the car. When the time comes I'll be removing any loose coatings first

 

[Dcal]

The epoxy is 2k, but not as nasty as isocyanate cured paints.
I would avoid breathing it or drinking it, but a "good" mask will do the job of protecting your lungs.
If you have asthma or other health issues, I"d be very cautious about spraying anything.

 

[Myles1970]

Remade the outriggers again, this time in 1mm. Used some heavy box from a trailer axle as a form

 

[Cosantoir]

For scale are those homes 8mm?

 

[Myles1970]

 

[Myles1970]

For scale are those homes 8mm?

16mm....was thinking of dimpling them, but they might be water drains...

 

[Myles1970]

Leading edge of rear wheelarche... This is the good side


... this is really just practice, as the plan is to go with the grp arch flares...

 

[Myles1970]

I'm sure the pics above have rearranged themselves



And inner repair welded:

 

[Cosantoir]

What was the body panel l like here? Did you cut it out to get to the inner arch or was that goosed also?

The top of my archs are similar to this so I'm wondering if you did it for the access or because nobody wants to weld upside down


Also the little flap of extra material you welded in is that copying something that was there already or is this to allow you to weld up to the edle of the material with less risk of blow through?

 

[Myles1970]

What was the body panel l like here? Did you cut it out to get to the inner arch or was that goosed also?

The second pic in post 204 (I managed to swap them around somehow ) shows the corrosion on the outer panel... it was actually worse than the inner...

The top of my archs are similar to this so I'm wondering if you did it for the access or because nobody wants to weld upside down

No, I just started with what I could see... then cleaned up surface rust on the inner arch, there was packing in there which may have encouraged any moisture to stay?!
...looking at the top of the arch, the flange is a bit ropey, I'll probably spin the shell around on the rotisserie and attack it from the inside of the wheel well

Also the little flap of extra material you welded in is that copying something that was there already or is this to allow you to weld up to the edle of the material with less risk of blow through?

Yes... my thinking was more material: more room for heat to dissipate... I trimmed it afterwards