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Old 16th October 2019, 01:56 PM   #81 (permalink)
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So thats enough tempting with fabrication and exotic chassis modification.
Back to rust repairs...........

This is what the drivers side chassis leg ended up looking like before primer.
Hopefully you will agree quite a change

017a4275925a0db68b41bdb6e9e5d3f856b58e2474.jpg

012dc3c7af48e53fa2aec643d34a955c689374a169.jpg

01ea7615895ce15a5f83c9f69272a07aa10932f85d.jpg

The blue/balck paint is a rust converter recomended by Steve Richardson (Facebook Skyline restoration Guru)

I am not going to bore everyone with primer picture so onto more rust......
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Old 16th October 2019, 02:36 PM   #82 (permalink)
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So back to the (worst) rust on the passenger side.
Having learnt the techniques and what I needed to keep and how to quickly get it apart I made a start on the passenger side sill. Firstly off with the outer skin

As you can see it is really crusty

01bd433f4f70d941ccf99c57306cff1ff4a6203c60.jpg

This is where I cut the rear quarter to be able to get access

01b80476bfaee98297c8b3676f38538d3ac9dbc295.jpg

A per the otherside, I now know this complete panel will come out for replacement. I also cut all the rear sill off and will use the other side as a reference as the remaining bits are so rusty.

0193dc45b168279d1b939609d94035763f51d5c8df.jpg

01c79cfe6d108ca81ea1c0d0980e0af42161921087.jpg

0168732f205f631cf198477c9b1e75bc1ab47124bf.jpg
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Old 16th October 2019, 02:42 PM   #83 (permalink)
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Inside of the rear crossmember cleaned up

01fb8c89098336363eeb97d1417b0eac26c29a38ad.jpg

Hear I have missed one photo but this is with the second under seat skin removed

01eb4df7dc76b2406fab4a7a8dc8a299ff96a12455.jpg

01d0a45d818bd93ac877e33f07509057982966b408.jpg

Complete sill removed and back to good metal

019d87ffb074399965b883ac90d0cc986a82f93f56.jpg
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Old 16th October 2019, 02:48 PM   #84 (permalink)
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The rear floor was worse than the otherside, sorry no picture but this is where the donor car cam in handy.

Complete replacement floor section shot blasted.

0199d624f9a0f5ca1ad5f20332ab227f918eaa7dd3.jpg

018525db1c12156a5fe5c8bc558d1a3da0517506f7.jpg

It was then separated and from the inner sill and spliced into the original floor, as per the other side by undoing all original welds and then seem welding across the loin into the existing floor

0194ab50fa3c51ba99e5ebf6599f631fd1f5ebe065.jpg

You can see from the hole that as per the other side the three layer that form the seam at the end of the floor need reconstructing. This panel is the first
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Old 16th October 2019, 02:54 PM   #85 (permalink)
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So this is a repeat of the other side, first repair inner sill (blue/black is rust treatment paint not rust)

0188a88d8cae32ed24024c64e0de3c62febc1948c5.jpg

013b002dd27d09270db09367b3a66219ece569a858.jpg

The second layer of the rear floor was then added back in and spot welded in place.

0120af062cb6465c168a03a2ec8519da61b098ccfc.jpg

010b2b1e11eff706aef97c369919344b6450a9c173.jpg

01543b04c6854abdcc434d0f3880aee3113aa44ade.jpg

Almost done
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Old 16th October 2019, 02:59 PM   #86 (permalink)
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So the big hole then needs filling with a new rear inner sill

01bd2f6ae69628a2aeae61d6942d7c7b5d3ed41716.jpg

Used the sizes from the drivers side I made a replacement and fitted

010a88fe4fabe1237a0a729f087f85f2025884ac26.jpg

Trial back in the remain of the what i'll call rear sill strengthening plate (as you can see there is not much left of it)

01f87fa79b1653311042b0f8ba52d1f836200d214a.jpg

So make a new one using CAD (Cardboard aided design) and fit

01892dd16780686c94976df13643a26fcdace7453d.jpg
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Old 16th October 2019, 03:14 PM   #87 (permalink)
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Then as per the otherside simply make a replacement corner for the arch panel (see previous description as to how to do this).

Interestingly for some reason I screwed the bead rolling up on this so ended up making a second one (pictured)

Note the remaining rust on the top of the inner wheel arch wont be left, but I'll do that later once the sills are on the the rear quarters are cut off

01a68bdbf7ecb09ac88c4e59206b02885cfd280cab.jpg

Now to the most difficult part of the whole car. Here you can see what I will call the rear sill support panel. As you can see only 1/3 of it has survived although actually better than the other side.

I decided to repair it in two parts, and this is where I now needed the sill trial fitted to judge the final shape

019f530862c18e87fc2fb8e7f8a8270dcf2f492095.jpg

Dont worry this crusty edge will also be replaced

018351a7841cc239f5ac6cd8875f4a630f8ab9441e.jpg

But first
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Old 16th October 2019, 03:22 PM   #88 (permalink)
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So first some more CAD

01487ad9f70443c732d76a821b5bb6483db2effc5b.jpg

0120bbb512f4819ad52a0edb4f157fba420f86b5c9.jpg

Tacked in place and rear edge replaced

01fe59685f925851ec0054126e786cda42dfbe06fd.jpg

0186207f05e37dfffb60a3a2157dfa3ea4fcf10d92.jpg

The end result after flapper wheeling I think is quite good. Pity it will never be seen as will be covered by the front edge of the rear quarter panel

At this point I decided I wanted a proper spot welder before continuing as the next step is to fit both outer sills.

So while I looked for one to buy I had a look at the the front chassis leg / arch / bulkhead. It didn't look pretty.......
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Old 16th October 2019, 03:25 PM   #89 (permalink)
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Quote:
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Bumped for an update, come on Dave.
Thanks Kev, it's good to see the update to your thread gives me some enthusiasm as to what mine can look like when finished.

How much I look forward to paint........ & carbon panels really looking forward to starting making them
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Old 16th October 2019, 03:32 PM   #90 (permalink)
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Please feel free to add comments questions to the thread
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Old 16th October 2019, 03:37 PM   #91 (permalink)
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This side was far worse than the other side

Crusty
01cc58173ae2ee4effc74ee6f5ab8f9da432c23cac.jpg

Holes
011577fbb7beb87f5b20d82fe09656e646bb6a4d0a.jpg

More holes
01b6b6c16ce54a4ffc3ff9f32713428f8c9f0a7c8e.jpg

More general crusty horidness, many would be tempeted to leave like this, but these panels need lifting off to expose the root of the issue
018736aa8d4a4f54587b36655be0b69a76bcb7d464.jpg

Look at all that rust hiding under the seem
0129eadf026d7a9e82149a9a726f9792240665c29a.jpg
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Old 16th October 2019, 03:40 PM   #92 (permalink)
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More S15 info please
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Old 16th October 2019, 03:40 PM   #93 (permalink)
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Based on the experience of the otherside and now having this inner wing panel from the donor shell I decided to completely cut this panel out.

Exposing the full crustyness of the bulkhead

0120c12a6d8fa329e83f7720a4c3cb0c79457d8459.jpg

So out with the grinder and 1mm cutting discs
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Old 16th October 2019, 03:45 PM   #94 (permalink)
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Cut out the rot

0113c1b1c4bbe698028cedfa0e1a6b4f44f4db8e42.jpg

Cut matching panel from donor

0155941fe1472026323352fd5bd030c7e9f8c60daa.jpg

Weld in
01fe58bd0e667ca00f9b3b8268a979dde4dbe12a11.jpg

Sand flat
01c10e9643bcbc7a8a76aaf2eda0459cd0723eb782.jpg

Hopefully you agree, as good as new
0195108f4f1bea1baaf3a8fb1994b2ea99dd701a90.jpg
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Old 16th October 2019, 03:50 PM   #95 (permalink)
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So what lerks beneath the inner wing panels on the chassis leg, yes more rust
one layer removed

01bd192576acdde031bc1de52ed4a7de0c03564e7c.jpg

010e560ace79993fde55bb01638a7fc843475a9c89.jpg

Finally top edge of chassis leg removed.

0158af685b02bc6b740289b541326ee8cd2fd04eaa.jpg

Some advice to anyone doing anything similar my advice is make the biggest panels possible, they are much easier to work with and it ensures you get back to good metal when you weld them in.
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Old 16th October 2019, 03:58 PM   #96 (permalink)
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Sorry no CAD pictures, but simply make a template cut from I think 2mm from memory as chassis leg is much thicker.

Then weld in:
0171b2c09b650545c90d0cf023aab9576368f21ffb.jpg

015a3e087b9194c975b3411a812a2f73e9439d4409.jpg

Then grind flat, here I have not ground back as much as other panels as I want the strength and it will be covered in some form of under seal so you will never see anyway

01979b933665906e6412b6406a69c7105ead865a75.jpg

01a93f08610c727a35f71bcbb5f666019bb6d81070.jpg
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Old 16th October 2019, 04:01 PM   #97 (permalink)
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Found picture of how I made the panel, as you can see it has a recessed feature

01e12ef042f711ceae652751ba14a7710bdc4873a8.jpg

017814bf7531bf661a515a3b687963f217153110a3.jpg

The tools are really simple, just beat it over a section of round edge bad, the result looks pretty OE

01312d31fc61f18a601a3b261d3cc252f0322da2c4.jpg
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Old 16th October 2019, 04:25 PM   #98 (permalink)
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Quote:
Originally Posted by BenTaylor200 View Post
More S15 info please
No problem i'll grab some pictures, the VE conversion seems surprisingly simple although I think my turbo selection is now wrong

I still need some simple bits if you can help
- Standard size crank
- Water neck
- Thermostat housing
- Standard crank pulley
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Old 17th October 2019, 10:29 AM   #99 (permalink)
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Quote:
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No problem i'll grab some pictures, the VE conversion seems surprisingly simple although I think my turbo selection is now wrong

I still need some simple bits if you can help
- Standard size crank
- Water neck
- Thermostat housing
- Standard crank pulley
I think I have a set of Supertech valve springs and titanium retainers for the VE head (I bought them twice by mistake!!)
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Old 17th October 2019, 04:18 PM   #100 (permalink)
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Quote:
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No problem i'll grab some pictures, the VE conversion seems surprisingly simple although I think my turbo selection is now wrong

I still need some simple bits if you can help
- Standard size crank
- Water neck
- Thermostat housing
- Standard crank pulley
10 years ago I'd have had all of these, had to downsize my parts hoard to make room for more cars!
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