[body_work] Floor...

[DamirGTI 323]

 

.. temporarily sprayed with zinc primer until i finish all the metal work on the shell and will then apply an light smear of body filler on this area .

 

......

[DamirGTI 323]

B-pillar joints from the inside

 

Found one hole :

 

 

 

Cleaned off factory seam sealer all around the B-pillar inside joints :

 

 

 

... and fully seam welded all the panel joints :

 

 

 

... afterwards , as usual , sprayed with zinc primer and will be seam sealed prior to painting ..

 

.....

Edited January 18, 2009 by DamirGTI

[DamirGTI 323]

A-pillar area

 

Found some rust and cracked metal beneath rubber weather strip :

 

 

 

... cleaned off the rust and re-welded the cracked area :

 

 

 

Decided to stiff this a little bit more (as i did on the other RH side , form the inside and outside of the shell ..) , seam welded the sill to the front frame :

 

 

.. zinc primer o top of the welds , and time for a little break :

 

 

Damir

Edited January 18, 2009 by DamirGTI

[EdCherry 34 1 Cars]

You continue to amaze me!

[DamirGTI 323]

Thanks ! well , must admit - i'm a little bit sick and tired with this constant grinding/welding/cutting dirty odd jobs but it'll soon be over just a few bits to sort out then painting job and will be on the road again .. i can't wait to sit back , start up the "rusty rocket" in the Sunday morning and run away up to the hills

 

Damir

[Roman 0]

respect what hold this car together before???

[DamirGTI 323]

what hold this car together before???

 

Body filler .. mostly this the LH side wasn't "too bad" but the RH one was real s*it (the floor mainly , as it's been T-boned on the RH side and really badly repaired afterwards hence the amount of rust on and around the floor panel on the RH side of the car ..)

 

Damir

[iamjackiechan 0]

i read loads of threads with people welding up so much rust damage, i havent found a single spot of rust on my hole car.

i feel rather gifted, dont mean to rub it in.lol

your doing an awesome job tho, really good fabrication

[ALEX 98 1 Cars]

I've seen better nick shells on the scrap heap how come it's got so much rust?!

Has the car got some sentimental value or something? as I can appreciate all the hard work you're putting into this.... but are you insane?!

I mean why put this much effort into a 205? they aren't that rare...yet!

That time spent could be put into better use in restoring one rather than building one from scratch, surly it would be far eiseier to find another chep MOT fail.

And you'd have plenty of spares too.

[Tesstuff 222]

Damir you are a star, but my God you are NUTS

[ALEX 98 1 Cars]

It remindes me of This

[j_turnell 134 3 Cars]

This has more rust than my Mk2 Escort! great effort in the repairing it, look forward to more pics!

[DamirGTI 323]

I've seen better nick shells on the scrap heap how come it's got so much rust?!

Has the car got some sentimental value or something? as I can appreciate all the hard work you're putting into this.... but are you insane?!

I mean why put this much effort into a 205? they aren't that rare...yet!

That time spent could be put into better use in restoring one rather than building one from scratch, surly it would be far eiseier to find another chep MOT fail.

And you'd have plenty of spares too.

 

Well , as said , was crashed on the RH side and badly repaired afterwards .. + it's an early non galvanized shell which doesn't helps either

 

Insane ?! - no , the thing is , i don't have a steady job for last 2 years (i got sick and some other crappy stuff has happened during the time .. long story anyway never mind ..) so i do not have the money to buy better car/shell and make something out of it .. i would if i could afford it , but i can't ..

Anyway i said in the start of this thread , i have one more 205 (it's not perfect but better than this one that's for sure .. but that one needs full respray and insurance/MOT and , again , i don't have the money for all this) , with this rusty one i thought why not to try and fix it and learn a little bit more about repairing bodywork ? which can be handy experience in the future , and i did learn a lot of new stuff , such as how to -> MIG weld (much better than i did before must say ) , cut/bend/shape the sheet metal , rust removing techniques , stuff about various paint types , using body filler , painting etc. etc. ... it's not costly repair like for instance full car respray , i dunno if i did spend more than 150 quid so far doing all this job .. but yes it's very dirty and time consuming job ..

 

If nothing , this will be a good practice for future projects .. just need to learn how to make a full car respray

 

Damir

[cybernck 400 1 Cars]

^ and in addition to that, 205 GTI's actually *are* rare like that around here,

especially good ones and not cheap / plentiful / easy to reshell as in the UK .

[DamirGTI 323]

That's right it's really hard to find good un 205 GTi over here , 5 or 6 years ago you could choose in between a few samples which where for sale all in the same time , now it takes up to 6 months or even more to until you'll spot just one sample for sale ! (and that one will usually be rather tired car , rusty , crashed , molested etc. etc. ..) ... I've been looking around for just a shell for re-shelling this rusty rocket , but that was mission imposible , after long searching i did find one shell but with "funny paperwork" and another one which was nearly as bad as this one in terms of investment in order to make something out of it .. on the other hand i've been offered to buy 3 good un complete 205 GTI cars but , as said , i needed more money in order to do so (they where from 1500 up to 3000 Euros .. i didn't have neither a 200 Euros in my pocket )

 

I could sort this out on the easier way if i was allowed to import a car/shell from the EU (Italy) but that wasn't possible due to Croatian car importing regulations ...

 

Damir

Edited January 20, 2009 by DamirGTI

[ALEX 98 1 Cars]

Just ralised your not in the UK. Sorry. my bad.

I was assuming the materials and welding rods would cost as much as a donor car, as you can usually find a good shell around here for around 150 pounds/euros.

Also the diesel shells are the same as the Gti ones.

Edit: Dean Hunter Peugeot spares usually has one in he breaks for spares, usually scraps the shells as he can't get rid of them, He sold a minter non sunroof one on Ebay about 2 years ago for less than 150

Edited January 20, 2009 by ALEX

[DamirGTI 323]

I know , i've seen a lot of very good clean cars on the scrapyards in the Italy but as much as i tried i couldn't sort out the importing bit - it's not possible to import a car from EU countries if it's older than 7years .. i have some contacts in the customs office but neither with their help i couldn't do anything against the importing regulations and that's it ... could just sit back and look at how they where lifting up this 205 cars with forklift and throwing them into the press

 

Damir

[lemmingzappa 75 1 Cars]

Really nice work, I certainly couldnt do it !

[platty 1]

I scrapped a 205 with less rust than this, your a braver man than me taking on this much work, hats off to you.

[ALEX 98 1 Cars]

I scrapped a 205 with less rust than this, your a braver man than me taking on this much work, hats off to you.

 

Read the thread, he has his reasons.

[BERTMAN 40 1 Cars]

reading this makes me feel better about tackling the tiny amount of rust on my front panel (compared to this anyway)... nice one damir!

[DamirGTI 323]

Cheers lads ! project is in final stage now , just few more days and it'll be back on the road .. i have a lot fresh pics , will add them later on

 

Damir

[DamirGTI 323]

.. closing stages of the odd rust busting project :

 

Some rust spots on the LH side of the floor , i left this soaking up in the phosphoric acid for say 3 maybe 4 weeks , the acid did lift off some and what was left was this the back areas :

 

 

... cleaned up the surface with 3 different grades of sanding paper (i did the sanding bit with the acid , "on wet" ..) and afterwards with angle grinder and 2 types of wire-wheel attachments (some mild ones ..) .. this was as good as it gets :

 

 

... and Loctite 7505 on top (just to be sure ! but will keep an eye on this area frequently ) :

 

 

B-pillar joints , applied filler , high build primer on top and did a bit of modeling :

 

LH side

 

 

RH side

 

 

... and painted :

 

LH side

 

RH side

 

 

.........

Edited February 13, 2009 by DamirGTI

[DamirGTI 323]

.......

 

.. and finally , floor panel respray !!!

 

Few coats of primer :

 

 

 

 

 

.......

[DamirGTI 323]

.......

 

..and few coats of paint on top :

 

 

 

 

 

 

 

 

Damir