Gas shouldn't be a problem. The local BOC is open tomorrow so i'll just go and swap it over. So far i've used about 3kg of MIG wire all up.

MIG gas replenished and i got a couple of spare MIG tips but it's too bloody hot in the garage today even with a fan going. Also got some spray on zinc paint for the inners of the C pillar areas.

Some more work done today after spending a couple of hours getting some repair patches from whooligan

Patched a rust hole in the passenger kick panel.



Stripped the paint off the C pillar in readiness for welding up.



Patched two holes in the passenger sill and cleaned up the welds on the A pillar.

PS C pillar vents plugged. Also removed the piece of foam rubber that holds the water to the bottom of the pillar and painted the interior of the pillar with Zinc paint to hopefully stop the rust. Started on the rear scuttle corner but i'm going out for tea so i've had to cease work.

Hi Steve,

Great progress Everytime your thread pops up with a fresh post I know we're in for a treat[:p]

Cheers,

Phil.

Cheers Phil. It's a bigger job than i first thought but i'm having lots of fun doing it. Rear scuttle is next, followed by the boot surround, rear wheel wells, drivers side C pillar and drivers footwell. I've got about twenty plugs to weld into the floorpan and interior, a couple more gussets in the engine bay then attach the new front and finally the big one, fitting the alloy arch kit.

some great work going on steve. always love seeing updates

Worked on removing the rear scuttle and repairing the corners today.

First job was to remove the old scuttle plate. As it's being binned I ground out the spot welds as this is much quicker than drilling them. This allowed me to have a look at the corners.

Passenger side one is knackered.


Drivers side one is actually pretty good. All it's getting is a coat of POR15


The rear minus scuttle.


Welding in a piece from a donor car. I welded in another bit but didn't take a photo of it.


Repaired corners with some POR15.




Next job is welding the new rear scuttle on.

Remembered that I need to paint the internal surface of the new rear scuttle so I dug out the POR again. Seeing as I had it open I then painted a few more bits including the end of my nose. Now I have four days of thinking I have a fly on the side of my snoz. Fun Fun.

New rear scuttle.



Other end.



Inside of new heater plenum cover.



Bottom of the new A pillar.



Join between A pillar and kick panel.



Hidden part of the front crossmember.



Outside of the footwell repair and the seam welds done earlier.



Repaired firewall and heater bowl.



Rear C pillar vent area.



Also bought a set of vice grips to help hold the rear scuttle in place while I weld it in.

I've been watching your progress with interest. I have recently done the heater section and bottom of the rear window plus a boot floor on my wifes RS 4 door. Mine this week made it into primer and should have the engine bay and door jambs painted by the end of Wednesday.

Having done it i dont envy you but am impressed with the job you are putting out.

Gareth