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Discussion Starter #81 (Edited)
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

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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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Discussion Starter #82
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

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

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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.

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Discussion Starter #84
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.

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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

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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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Discussion Starter #86
So the big hole then needs filling with a new rear inner sill

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

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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)

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

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Discussion Starter #87
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

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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

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Dont worry this crusty edge will also be replaced

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But first
 

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Discussion Starter #88
So first some more CAD

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Tacked in place and rear edge replaced

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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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Discussion Starter #89
Bumped for an update, come on Dave. :popcorn:
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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Discussion Starter #91
This side was far worse than the other side

Crusty
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Holes
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More holes
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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
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Look at all that rust hiding under the seem
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Discussion Starter #95
So what lerks beneath the inner wing panels on the chassis leg, yes more rust
one layer removed

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Finally top edge of chassis leg removed.

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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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Discussion Starter #96
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:
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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

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Discussion Starter #98
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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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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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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