Sierra XR4i full restoration.

[Domdom]

OK, the initial test of the paint and gun combo. I did the engine bay and the inside of the tailgate. Sprayed at 1 bar from a Devilbiss GPG with a 1.4 fluid tip. I also added a tad more thinners than normal so I could turn the pressure right down for all the nooks and crannies.

Only half a litre of paint used, which wasn’t enough to get the second flow coat on but I did get all the fiddly bits done in the engine bay. Really awkward getting in to all the corners without creating runs on all the surrounding bits though, took ages. The really tight corners were painted at 10psi with the flow screw wound almost right in to prevent runs. Also, the slam panel and other bits which I will get to when the outside of the shell is painted were only over sprayed as a side effect of doing the inside of the engine bay. The outside can’t be reached properly as it’s still on the jig.

It needs another coat, which I will do later on today, but I’m pleased with it so far. What do the collective think?

 

[Domdom]

Well, I put the second coat on late Saturday night which went on well. Sprayed at 1 bar, with 30% thinners to help blend in the dry bits. Low pressure really helps keep the overspray down and this GPG gun is still even throughout the fan at 1 bar.

Of course it was quite windy with a few rain showers overnight so I do have some dust to deal with. More than I would have liked anyway. But, I sanded out a lot of it with 1500 wet and dry, used wet, and put the polisher over it to get an idea of how it will come out and I’m happy enough now. Oh, flies. Damn things. Got 2 of them in it.

What I am going to do before going too much further is to hoover the place out. I did damp it down with the mist spray from the hose before I did this, but looks like it dried out rather quickly. I reckon get the place as clean as possible, then wet it all down before painting again. Possibly do future sanding outside as well.

 

[marlinspike]

This is really coming along. I'm massively impressed with your painting skills.

 

[Domdom]

This is really coming along. I'm massively impressed with your painting skills.

LOL, I’m not. I put some Jotun87 on the bonnet last night. Rushing a bit and was painting under the garage lights but looked at it this morning and I got a colossal run in it . That’s going to take a bit of sanding out No pictures, too embarrassing.

Note to self, paint in daylight, and don’t rush.

Thanks for the compliment though.

 

[SierraV6]

LOL, I’m not. I put some Jotun87 on the bonnet last night. Rushing a bit and was painting under the garage lights but looked at it this morning and I got a colossal run in it . That’s going to take a bit of sanding out No pictures, too embarrassing.

Note to self, paint in daylight, and don’t rush.

Thanks for the compliment though.

Just take it as a lesson learned; the rest of what you’ve done looks superb though!

 

[RWD3M]

Hey @Domdom !

Gone a bit quiet, any progress lately?

 

[Screwdriver]

Wow. Looks good enough to eat!

Nice work.

 

[Domdom]

Hey @Domdom !

Gone a bit quiet, any progress lately?

Yeah, a few bits. Work, and a holiday in Mexico sort of got in the way.

Fitted up the rear bumper at the weekend, which meant taking it off the jig. Didn’t fit. Damn thing. All I wanted to do was fit the front edye bumper hangers which I don’t have reference measurements for. Basically trial and error, which showed up this bad fit when we trial fitted the bumper.

So the OSR quarter, especially around the fuel filler where I had to rebuild it from scratch pretty much, yeah it’s all wrong. Too much gap between body and bumper. It’s all properly out of whack to the point I but the quarter panel open again to get the gap right. Bridged it with a couple of steel strips and now have an unholy mess to sort out again. I was also jetlagged when I was doing it which is less than ideal. Bad tempered, tired and peeved are not a great combo.

will get some pictures when I get back on it, maybe this coming weekend.

 

[RWD3M]

Yeah, a few bits. Work, and a holiday in Mexico sort of got in the way.

Fitted up the rear bumper at the weekend, which meant taking it off the jig. Didn’t fit. Damn thing. All I wanted to do was fit the front edye bumper hangers which I don’t have reference measurements for. Basically trial and error, which showed up this bad fit when we trial fitted the bumper.

So the OSR quarter, especially around the fuel filler where I had to rebuild it from scratch pretty much, yeah it’s all wrong. Too much gap between body and bumper. It’s all properly out of whack to the point I but the quarter panel open again to get the gap right. Bridged it with a couple of steel strips and now have an unholy mess to sort out again. I was also jetlagged when I was doing it which is less than ideal. Bad tempered, tired and peeved are not a great combo.

will get some pictures when I get back on it, maybe this coming weekend.

Oh dear, sorry to hear.

I know what you mean, not the best state of mind to be tackling this sort of stuff. Still, look on it as an opportunity! You'll make a great job of the corrections, as you already have done on the rest of the car

Looking forward to more pics.

Onwards and upwards!

 

[Domdom]

Righto, time for an update. I’ve not been in the workshop at all aside from putting the Christmas decs away. Far too cold, work very busy, and I’ve not been in the right frame of mind after the disappointment of the rear bumper not fitting.

Anyway, I cut a slot where the bodywork was too far in, with the intention of letting some metal in there. The difficulty was knowing how much to let in so it had to come off the jig (again), which is a right old faff, especially on my own.
Back on axle stands with the rear bumper fitted, I then made a judicious application of the hammer using some wooden blocks to gently knock the quarter panel out until it looked right against the bumper.

Cut a couple of bits of scrap to weld in temporarily so the gap wouldn’t move whilst putting it back on the jig.

So, the gap. You can make out the temporary brace bits. I had to do quite a bit of fettling with a hammer and dolly to try and get the edges right, no mean feat with having to hold the dolly with my right arm shove in through the hole for the back light. It also meant hammering with my left hand and I’m right handed.

So at the edge nearest the arch, rather than try and cut a piece to fit that, I cut a 4mm arc rod down, knocked the flux off it, and used it as a gap bridge. Turned out OK as it goes. Still some hammer and dolly work to be done but needs my brother to hold the dolly as I don’t have 5 foot long arms with 4 elbows on each one




Packed up for today, can’t feel my toes, fingers etc. Still -5 here.

 

[RWD3M]

Righto, time for an update. I’ve not been in the workshop at all aside from putting the Christmas decs away. Far too cold, work very busy, and I’ve not been in the right frame of mind after the disappointment of the rear bumper not fitting.

Anyway, I cut a slot where the bodywork was too far in, with the intention of letting some metal in there. The difficulty was knowing how much to let in so it had to come off the jig (again), which is a right old faff, especially on my own.
Back on axle stands with the rear bumper fitted, I then made a judicious application of the hammer using some wooden blocks to gently knock the quarter panel out until it looked right against the bumper.

Cut a couple of bits of scrap to weld in temporarily so the gap wouldn’t move whilst putting it back on the jig.

So, the gap. You can make out the temporary brace bits. I had to do quite a bit of fettling with a hammer and dolly to try and get the edges right, no mean feat with having to hold the dolly with my right arm shove in through the hole for the back light. It also meant hammering with my left hand and I’m right handed.

View attachment 382018

So at the edge nearest the arch, rather than try and cut a piece to fit that, I cut a 4mm arc rod down, knocked the flux off it, and used it as a gap bridge. Turned out OK as it goes. Still some hammer and dolly work to be done but needs my brother to hold the dolly as I don’t have 5 foot long arms with 4 elbows on each one


View attachment 382029

Packed up for today, can’t feel my toes, fingers etc. Still -5 here.

Good to see the update and great that you are getting your mojo back!

Onwards and upwards!

 

[Domdom]

Righto, my brother is here this weekend. Combination of my birthday and the Classic Car show at the NEC. Spent a while in the workshop sorting the rear bumper mounts.

These are awkward as the bumper has to be in place to know where to fit them, which means the shell had to come off the jig again. That’s a mission to be frank, takes about an hour to do it safely.

Then we come to the mounts themselves. Not available as a replacement panel and I had about half of one rusty relic, so this had to be repaired and them the other one was made from scratch.

Anyway, they’re on and the shell is back on the jig ready to touch up the red Raptor bed liner on the underside.

 

[Superbad]

I remember tackling these areas on mine in my early days of becoming acquainted with welding...still need to finish my XR4i

 

[500e]

Nice little Turbo Technics twin turbo v6 engine and gearbox festering under a tarp in the yard if you are interested.

Bob

Had a 4i for a short while (2 weeks) all the TT mods engine suspension gb drive shafts etc, had to go before my licence a real hooligan car

 

[Domdom]

I remember tackling these areas on mine in my early days of becoming acquainted with welding...still need to finish my XR4i

I would offer to help but need to get this one finished first

 

[Domdom]

Well, thats the end of the welding, it’s all done. Now concentrating on getting it into paint. Major milestone for me and it was a good feeling to put the welder away last night. I enjoyed doing it, but it was a mission. Looking back at some of the photos I can’t quite believe I did all this.

Overall though lads, I know I learned to weld with stick over 40 years ago, and the principles are all quite similar, but without this forum I think I would have had a lot more problems. The advice has been stellar, and not just for the welding. Tin bashing is another thing I’ve learned and it’s been essential for this one, having to make so much of it myself. Really appreciate the hints, tips and advice. You’re a bunch of diamonds!

Classic car show today where I can pick up some more abrasives ready for the primer, and drool over some lovely old crocks in far better condition than this one. Maybe even score some bargain tools I don’t need

 

[SierraV6]

I remember tackling these areas on mine in my early days of becoming acquainted with welding...still need to finish my XR4i

Progress on mine has stalled completely but I'm hoping to (re)start work on it this year. Oddly the rear bumper mounts are intact on mine!

Well, thats the end of the welding, it’s all done. Now concentrating on getting it into paint. Major milestone for me and it was a good feeling to put the welder away last night. I enjoyed doing it, but it was a mission. Looking back at some of the photos I can’t quite believe I did all this.

Overall though lads, I know I learned to weld with stick over 40 years ago, and the principles are all quite similar, but without this forum I think I would have had a lot more problems. The advice has been stellar, and not just for the welding. Tin bashing is another thing I’ve learned and it’s been essential for this one, having to make so much of it myself. Really appreciate the hints, tips and advice. You’re a bunch of diamonds!

Classic car show today where I can pick up some more abrasives ready for the primer, and drool over some lovely old crocks in far better condition than this one. Maybe even score some bargain tools I don’t need

I've really enjoyed this thread so far, you've done a great job. I look forward to seeing the next stage!

 

[Domdom]

Ok, I did some more today. Was at a loose end after repairing the strimmer and already in my scruffs so why not.

Have to say, petrol strimmers are hateful things. Stored carefully over winter, with some of that super fuel stuff from the machinery place, at 5 quid a litre I might add. No bloody different to the previous year on regular unleaded, I still had to strip and clean the carb before it decided to play ball.

Anyway, lots of sanding and shaping to try and get the rear quarter panel as it should be, especially the swage line. It’s coming together now although the line is still a wee bit high towards the back. This is the panel where I cut out the filler cap area so I could repair the panel behind it, a decision I am starting to regret somewhat. In truth, there was no other way at the time and I should have removed the whole quarter panel but it is what it is.
A quick splash of primer to get it all one colour makes it a lot easier to eye up the panel and I reckon one more day will see it perfect.

No pics really other than that panel, but in between waiting for bits of filler to go hard I did a load of hand sanding round the fiddly bits in the door shuts and boot shut. Very sore (soft computer operator) hands now.

 

[angellonewolf]

Have to say, petrol strimmers are hateful things. Stored carefully over winter, with some of that super fuel stuff from the machinery place, at 5 quid a litre I might add

all this additives seam pointless to me only reason i can see is if you have an very old unit that does not have a way of priming the carb any that have a priming bulb inline or on the carb just the last time you use it finshed the job empty the tank while the unit is running and keep it running untill it stops so its empty
and thats it nothing in the carb to go off or go solid and cheaper as well

 

[minimutly]

Ok, I did some more today. Was at a loose end after repairing the strimmer and already in my scruffs so why not.

Have to say, petrol strimmers are hateful things. Stored carefully over winter, with some of that super fuel stuff from the machinery place, at 5 quid a litre I might add. No bloody different to the previous year on regular unleaded, I still had to strip and clean the carb before it decided to play ball.

Anyway, lots of sanding and shaping to try and get the rear quarter panel as it should be, especially the swage line. It’s coming together now although the line is still a wee bit high towards the back. This is the panel where I cut out the filler cap area so I could repair the panel behind it, a decision I am starting to regret somewhat. In truth, there was no other way at the time and I should have removed the whole quarter panel but it is what it is.
A quick splash of primer to get it all one colour makes it a lot easier to eye up the panel and I reckon one more day will see it perfect.

No pics really other than that panel, but in between waiting for bits of filler to go hard I did a load of hand sanding round the fiddly bits in the door shuts and boot shut. Very sore (soft computer operator) hands now.

View attachment 392641

First job is topcoat that swage line and look lengthways at it. Don't move on until you're happy, you'll see it every time you get in it and it will pee you off, but of course you know all this.