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Mk1 restoration

Posted: Sat Dec 09, 2017 10:17 pm
by John&Luke
Hi, so starting my next restoration project.

Managed to get my White Mk1 into the garage today ready to start a few months swearing, cursing, spending far to much but, hopefully getting there in the end.

Couple of photos to set the scene.

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Jobs will include, new sills /arches, new wings, straighten the drivers door were its be closed against the seat belt :naughty: bodywork before respray, and interior make over.

Target Summer Rally :?:

Look forward to menders advice and encouragement. I will need it!

A real menders project>

Re: Mk1 restoration

Posted: Sun Dec 10, 2017 11:15 pm
by Mazda Mender
:text-goodpost: :coffee:
M-m

Re: Mk1 restoration

Posted: Mon Dec 11, 2017 2:30 pm
by DavesBRG5
Always worth saving the white ones......Keep us posted :text-goodpost:

Still need a decent white passenger wing for mine if you come across one.

Re: Mk1 restoration

Posted: Sat Dec 30, 2017 2:22 am
by John&Luke
Hi Menders, Merry Christmas to everyone.

Little update on my latest project. Managed to get some time today to start the process of removing the rot.
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On first inspection the arches don't look to bad.

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However as we know, its what you can't immediately see that can be the problem. A good inspection underneath showed the effect of a poorly applied underseal. Its formed a second skin that has delaminated from the metal and formed a prefect water trap leading to a a completely rotten inner sill. I could literally pick off the underseal in big chunks.

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So more that I bargained for. But a 2 owner 50k miler has got to be worth some effort?

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Front wing is also a goner, inner wing wire brushed and rust treated ready for a decent Upol primer.
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Re: Mk1 restoration

Posted: Sat Dec 30, 2017 9:27 pm
by Mazda Mender
:text-coolphotos: :handgestures-thumbup: :coffee: :coffee: :coffee:
M-m

Re: Mk1 restoration

Posted: Wed Jan 03, 2018 11:02 pm
by John&Luke
Update on progress made. Door and rear bumper removed, typical issue with the 8 off 14mm bumper retaining bolts in that one started spinning (luckily the one of the bottom ones) and had to be cut off, and two snapped the retaining bolts due to corrosion. Door was less problematic.

In between times, the inner wing was wire brushed and de rusted, rust treated, and etch primed.
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Moving back to the rear arch, the bottom section is gone and needs replacing.
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and whilst the inner wing looks not to bad, after a more detailed inspection it also needs replacing. To just clean this up and rust treat would be a false economy in my opinion. see photos below
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So a complete re-fabrication, which should make spot welding the replacement wing in place straightforward at least :-D

To fabricate the inner wing I'm using 25mm angle section, which I cut into manageable lengths. A metal shrinker/stretched is invaluable for forming the necessary curve of the arch. So starting at the bottom I made the most difficult bit. I purposely have made the return flange to wide at this stage so I can trim to the inner and outer arch profile to match (see drawn line).
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Once this section was made (about 2 hours work) as this needed cutting and welding to get the tight radius) I moved on to the next section. Here you can see this clamped in place. The stretcher being used to stretch the upright flange of the angle and hence form the main curve of the arch. Note the 4 cuts on the return flange in order to follow the inward radius of the arch. These will be welded together once finished.
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More of the same for the third and fourth section.
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and then a trial fit of the new inner sill.
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A good days work for me, not to many mistakes and a sense of achievement :coffee:
Next step will be to finish the last section of the inner arch and then cut out the old and start the welding.

As always, please if anyone spots any issues or mistakes please reply and let me know!!!!!

Thanks

Re: Mk1 restoration

Posted: Thu Jan 04, 2018 9:10 am
by fujikun
:text-goodpost:

Re: Mk1 restoration

Posted: Sun Jan 14, 2018 5:04 pm
by Brgdane
Lovely job


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