2025/05/01 18:55:56
martymexico
The jigsaw puzzle begins, so going to cut the best bits and weld together ?
2025/05/01 19:30:16
escortinadriver
Exactly.

The white one in the middle has the best skin. (Has a few pinholes) however the bonnet closing section (underneath at the front) is cactus.

I'll make it up from the other 2 and swap it in.

They are 310 pounds from expressed panels before postage!
2025/05/02 14:42:27
escortinadriver
Went to make a start on the bonnets today only to soon realise my blunt spot weld drill bits weren't up to the task, so have ordered some more and have moved to the rear of the wagon.

I removed the tailgate in preparation for some dent removal using the still unused spot welder/puller. I won't start until the new glass seal arrives as I don't want to risk destroying the seal if the new one is incorrect and/or won't fit.

In thr mean time I've turned my attention to the rear most (d?) pillar. It has the worst rust on the car. Unfortunately removing the pillar vent resulted in 4 snapped studs however luckily o managed to find a NOS one on eBay. Definitely not cheap!

Will see how I go with this one, it's been a few months since the welder was out.
Also some more photos of the bonnets I have to work with. More bog and rust than metal!





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2025/05/02 17:17:16
martymexico
Rear D pillar looks religious just floating there, yoikes..
If you know how to sharpen a drill, just angle it more flat, and maybe pilot drill first to stop wandering drill bits.
Looking at those repair sections if it's me I'll be building a new piece(s) , it don't gotta be spot perfect but not noticable to the untrained eye .
I remember I did the front bonnet slam piece on a mk1 that was about 500mm across just using hammer, grinder and welder going back 25yrs , had no idea what I was doing either.
At least option B is building you own!
2025/05/04 14:18:45
escortinadriver
OK, know I'm jumping around bit however the tailgate was on the stand and while I scratch my head for a bit before tackling the D piller I thought I'd give the dent puller a crack.

First impressions, not bad at all.
I obviously need some practice and should probably now look at some youtube videos for how to use it instead of experimenting on the car, however for the best part, it went well. Eg, I have no idea if I should have used the ring, key things or what I did. This was the first thing I picked up so went with that.

Discovered I'm better off cutting/grinding the fixtures off as wobbling them off tore holes in the very thin metal.

Ended up chasing my tail with the grinder chasing pin holes however it's much better than it was and will be good enough with a skim of filler.




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2025/05/05 12:51:18
deano
The dent puller was the tool for the job by the looks, that came out a treat.
No need now to watch YT's to see how to use it.
 
Sad when your tack welds are stronger than the car though when you go to remove.
Done that before too.
 
2025/05/05 16:50:22
escortinadriver
Had a few hours today so started filling in some more holes .
Few pinholes to chase and a bit more work with the sander however it's solid and better than what it was. There's much less work to do on this/driver side

Then I'll need to finish trimming and weld in the guard piece. It had a hole right through to the cabin (was a pain to fill). Surprisingly the footwell hadn't rusted out as a result. The underneath is now solid, and as it won't be seen, I'll also smother it with seam seal from under the dash and under the guard to protect it.




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2025/05/06 11:57:48
martymexico
Nice job there mate , soon we won't even know you've been there!
Just remember to fish oil or seal the back of the welded are if possible 👍
2025/05/08 15:30:43
escortinadriver
Got a bit more done. Guard patch in.

Stupidly manage to warp it whilst chasing holes and sanding too quick with too much in. It is only a few mm which is easily patched woth some filler and have to be realistic, the rest of the car is no where near straight anyway! 🤣




Now onto the next hole

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2025/05/08 19:50:41
martymexico
A warped panel from repairs is always better than rust. Good work
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