First panel done..

Although not overly chuffed with the result as I have blown through the original metal. Anyhow, it seems to be secure and is not *that* bad ;-)



Here we have the old panel having drilled out the spot welds with a 7mm drill. Cleaned up with a wire brush on a grinder.



Here is the repair panel; I'd bought the complete panel from Moss as I don't have any sheet metal kicking around and at least it saves the hassle of cutting and shaping... I've used the same technique to drill out the spot welds and then dressed the panel with a wire brush and beaten it flat again.


So, here we have the new panel offered up and clamped into position.


Couple of plug welds later and its secure...but

Spot the blow through as my ham-fisted attempts at welding cock-up!


These are the best thing to dress a weld: 40, 80 and 120 grit and much better than a cutting disk!!.

Now sat in front of the TV watching the Liverpool vs Luton match which a beer!!

The deed is done (or at least one side..)

So, a couple of hours with an angle grinder and this is what you end up with...


Almost off - I've cut well below the line I scribed earlier as it is easier to take off metal than to add it - just ask me how i know ;-)


Wasn't a lot left of the inside corner...


What was left of the inner panel


The rear looks a bit worse than I thought it would...


After a bit more grinding you end up with this - a slightly better place to start from.


This is the wheel arch from behind - looks a bit sketchy but...

From the front having wire brushed it, it looks a little better.




These last two show the bit that I sort of cocked up - rather than grind it I used a cold chisel which worked but has left me with some cleaning up to do tomorrow!!

Final measure

, originally uploaded by tobyanscombe.

This is the final measure before I start hacking away with a grinder...

The top line is the max height of the repair panel when fitted.

The middle section is the overlap area which will have a step formed in it to attach the new panel.

The bottom section is the scrap material

, originally uploaded by tobyanscombe.

This is the fitted up repair panel showing where the max line is derived from.

As you can see, the underside of the back of the wing is not in good nick!

Porker on the rollers

Image0002, originally uploaded by tobyanscombe.

just for a larf at the last rolling road session I organised in Croydon we stuck my girlfriends Boxster on to see what it could do...

I should point out that the rollers are only rated to 280 hence the line..

Rusty-Busty part X

, originally uploaded by tobyanscombe.

Passenger side looks to be in slightly better shape.

Rusty-Busty part IX

, originally uploaded by tobyanscombe.

The drivers side from in the boot - the boot extension looks to be a tad shot and you can see the hole in the wing!

Rusty-Busty part VIII

, originally uploaded by tobyanscombe.

This side was not as bad further back.

Rusty-Busty part VII

, originally uploaded by tobyanscombe.

The other side didn't escape...

Rusty-Busty part VI

, originally uploaded by tobyanscombe.

Same panel showing the holes near the bumper and lights.

Rusty-Busty part V

, originally uploaded by tobyanscombe.

Same shot with flash.

Rusty-Busty part IV

, originally uploaded by tobyanscombe.

Same shot as the last one but this time showing the boot extension has also gone...

Nice bit of daylight!

Rusty-Busty part III

, originally uploaded by tobyanscombe.

Passenger side inner sill looking from the wheel well. Shows the little bit of rust which has eaten away the inside.

Should be able to use some patch metal to clean it up.

Rusty-Busty part II

, originally uploaded by tobyanscombe.

...and here is the rear wing in all of its glory!

I've ordered a 1/4 repair panel for this - hope its big enough!!

Rusty-Busty part I

, originally uploaded by tobyanscombe.

Here's the passenger side B post showing a little bit of rust on the seam.