rear wing patch

[RaceDiagnostics]

My current thinking is to do a section like this.

 

[Wallace]

Is that the right hand side and you are holding the outer wing? If so, my first thought would be to disassemble all 3 parts and use them to repair the car from the inside out (as the car was built) or at least repair the inner section then add a larger section of wing and inner arch.

 

[RaceDiagnostics]

Thanks for the suggestion, yes it is the right hand wing, the bottom edge has an overlap that is spot welded and I think the inner and outer lip of the wheel arch is just glued together.

Any suggestions on how to dissolve or get rid of the foam?

Here is a pic from the underside.

 

[Wallace]

Looking at the panel from that side I think you might be best to repair the inner section then fit the wing repair piece using plug welds instead of the glue and spotwelds. Have you tried cellulose thinners on the foam?

 

[RaceDiagnostics]

I started to break down the donors, I'll then strip them of paint before cutting into the car.

I used this spot weld bit but the other type with the cutting saw blade is better. I ended up having to chisel a few of them apart I ended up going right through on a couple.

 

[RaceDiagnostics]

Back to it.

This is what the inside of the wing looked like, I had primed it then sprayed it with waxoyl 20 months ago when I tried to get rid of the rust first time round.

However the air vent is the big problem, it lets in lots of water and crud.

I made up a paper template and marked round it, tricky on a curved surface.

Then cut it out.

The primer and waxoil had not prevented the rust regrowing.

I then cleaned up what remained, part of the inner wing disintegrated.

So I cut it out and cleaned up all the surfaces with 40 grit.

And made up a patch panel from the donor.

And then welded it in.

Next I cut out an oversized patch from the donor.

Then fitted it over the wing and scribed round it.

And then cut out to the donor shape.

I then had to fettle a bit but am now almost ready to weld in the donor.

 

[RaceDiagnostics]

Sunday

On to the other side today, just as bad as the other side.

Another cut out of the inner wing.

And a patch welded in.

Getting access to the inner wing is tricky.

First I removed the amp/cd cage, the outer cage is held in by 5 bolts, the first three came out ok but the fourth captive nut sheared off, need to sort that out later.

The fifth fixing point is a nut in the middle behind the cage and can not be seen, you have to remove it by touch, the outer cage can then be manipulated out. You can see the stud for the fifth fixing point below.

The stud.

On to repair some of the wheel arch problems, this area was badly rusted so I cut it out.

And welded in some new metal.

Next I painted what I could with two part epoxy, ill strip back some of that for welding which I should get to in the next few days.

As for the two large air vents, I plan to glue in two patches using seam sealer to stop it all happening again.

 

[RaceDiagnostics]

Got another two hours in tonight, this time a couple of patches on he left rear wheel arch.

Cut out a couple of sections.

I cut a section from one of the donors and used a bit of 0.8mm sheet for the other section.

Stitched in both sections, I had a few problems with the glue between the sections blowing the weld puddle into a crater but continues to patch up.

Then ground them down, not perfect but it will do.

 

[marlinspike]

Impressive work. I always think wheel arch repairs look to be the trickiest bits to do. So easy to warp the rest of the panel.

 

[RaceDiagnostics]

The main event!

Here is my set up, bought second hand from gumtree, seems to be ok for this car body work.

I decided to go with magnets rather than the clips as they seemed to give too big a big gap.

Tacked in place.

Stitched up.

From the inside.

Ground down.

Fixed a few pin holes.

Other side.

Made up same "blanks" to seal off the stupid huge air vents.

And sealed them in place with seam sealer.

So the left wing is looking good but I have a bit of a kink in the right wing, wish I had a dolly set, will try to sort out with a hammer and filler.

 

[RaceDiagnostics]

Today's wepons of choice.

First I sanded back the paint from the repair.

Turns out that the P38 is junk, it went on very rough, this was after 5 mins of sanding.

Sanded with 40 and 80 grit.

Next the dolphin glaze, very smooth but it was going off fast in the heat today.

120 and 180 grit to get this.

On to the other side.

This shows how rough the P38 was going on.

My neigbour came out and took this pic.

This was the sander I was using.

Then the Dolphin glaze.

Once sanded I put on a few coat of Eastwood 2k epoxy primer from a rattle can, holding my breath for each pass.

Now from the pics below it looks pretty good, but it is not, in direct sun you can clearly see the areas of filler as it has not been feathered enough.

Now I could probably get it tright eventually but I am not sure how long it would take and as I plan to get both wings professionally painted I will also let them do the final coat of filler and sanding.

 

[Rocketman]

Nice job mate. Filler primer is just the job for feathering out filler. You can use it over the epoxy primer but just roughen it up before.

 

[RaceDiagnostics]

Thanks for all the suggestion, help and support for this project, I'll post up some more pics once it has been painted.

 

[steveo3002]

next time easy with the filler , wipe in a thin spread so its easier to rub down

looks like the last pic it was too far gone when you applied it

 

[RaceDiagnostics]

I got 3 quotes for painting the repaired area, round the wheel arches and along the sills, 400+vat, 500+vat and 600+vat, and am now thinking that for that money I could buy a couple of good guns, put in some kit to clean up the air from my compressor to be dry and oil free and have a go myself.

Do these quotes sound ok, or do they see the jag and double the price?

 

[marlinspike]

The latter, I suspect. I was quoted £150 to respray a Saab wing by a reputable bodyshop. I live in the northwest so it may be cheaper than other parts of the country but they seem expensive quotes to me. I suppose there is a fair bit of blending in to do, especially over the wheel arches, plus it is metallic.

 

[RaceDiagnostics]

I picked up the car from the painter this weekend, £500 all in. They redid my filler attempts, blended base coat over the repairs, round the wheel arches and along the sills then clear-coated the entire rear wings, sills and right rounds the back of the car. They have done quite a good job, I can see it because I know it is there but it is good enough. Just hope it last for at least 10 years. I should have cleaned the wings before taking the pics as they are a bit dirty after driving the car in rain today.

 

[Wallace]

looks good.

 

[tomsutton529]

Good job there mate, From experience a lot can be hidden with filler but getting the paint to look right is a real art.

 

[skotl]

That looks good. I admire your bravery and persistence