I recently joined the forum, so my plan is to post smaller and bigger jobs on the E9 in this thread. The first one here is one of the bigger ones!
When i put it away for the season, back in october. I made a list of what would need repairing for the next season. Before i got started on the list, I saw that the front left fender was starting to stick out more than usual. I, stupidly, took of the sill cover and found some rust. At first i didn't think it was so bad. But when i started to poke on it with a screwdriver, it was only the paint holding it together.
First I cut of a part of the front outer sill and revealed the A-pillar support, it did not look good, pictures below. There was also welded in som extra pieces of metal to the middle sill to substitute the rotted metal that was cut out. Too thin metal gauge and poorly executed. Since I have to buy the entire sills only to get a small section, why not change it all? So I cut off the entire outer sill and middle sill. Doing this, I had to take out most of the interior to weld in some reinforcements, so the car won't bend. When most of it was out, why not get it reupholstered? So i sent the front seats, rear seat, arm rests front and rear, door cards and senter console to a re upholsterer. The interior job will be posted in this thread later.
In advance; sorry for the low-quality cellphone pics!
Picture of the bottom of the A-pillar:
I cut of the bottom and revealed some art work. Some quality welding going on here.:
The middle sill didn't look too bad. Most of it was good metal.
Most of the outer sill was formerly just removed and not changed. I found parts of it in here. The rear fender was just welded over it all an covering it all up.
Where the triangle part is supposed to be, I found a fence post reinforcing the jackpoint. It was probably strong, but not beautiful. I would like my car mostly original structurally, so no place for a fence post in here!
Long story made short; I took it all of and started fixing the inner sill and recreating the triangle parts from pictures found on this forum:
2K epoxy primer:
Painted with a rust preventive "waterproof" paint. I used the same stuff outside mye house on some rusted steel 5 years ago, and it still look like new.
The other sills got the same spa treatment on both sides:
Made a new piece at the bottom of the wheel arch. Dont ask me why i painted it on the outside before welding it in place, I dont know!
The piece in place:
Bottom of the B-pillar was in god shape, so i just sandblasted both sides, painted it with 2K epoxy etc and welded it back in.
A new A-post bottom in place:
All-black. I actually regret using black because i kind of hides all the hard work
Put the door back on to ensure panel gaps. Notice the inner wheel house is now fixed properly. Sadly forgot to take pictures.
Rear fender (quarterpanel?)
Looking like a car again:
Not exactly an original-paint car
This is right about where I am in the process. Will post more soon
When i put it away for the season, back in october. I made a list of what would need repairing for the next season. Before i got started on the list, I saw that the front left fender was starting to stick out more than usual. I, stupidly, took of the sill cover and found some rust. At first i didn't think it was so bad. But when i started to poke on it with a screwdriver, it was only the paint holding it together.
First I cut of a part of the front outer sill and revealed the A-pillar support, it did not look good, pictures below. There was also welded in som extra pieces of metal to the middle sill to substitute the rotted metal that was cut out. Too thin metal gauge and poorly executed. Since I have to buy the entire sills only to get a small section, why not change it all? So I cut off the entire outer sill and middle sill. Doing this, I had to take out most of the interior to weld in some reinforcements, so the car won't bend. When most of it was out, why not get it reupholstered? So i sent the front seats, rear seat, arm rests front and rear, door cards and senter console to a re upholsterer. The interior job will be posted in this thread later.
In advance; sorry for the low-quality cellphone pics!
Picture of the bottom of the A-pillar:
I cut of the bottom and revealed some art work. Some quality welding going on here.:
The middle sill didn't look too bad. Most of it was good metal.
Most of the outer sill was formerly just removed and not changed. I found parts of it in here. The rear fender was just welded over it all an covering it all up.
Where the triangle part is supposed to be, I found a fence post reinforcing the jackpoint. It was probably strong, but not beautiful. I would like my car mostly original structurally, so no place for a fence post in here!
Long story made short; I took it all of and started fixing the inner sill and recreating the triangle parts from pictures found on this forum:
2K epoxy primer:
Painted with a rust preventive "waterproof" paint. I used the same stuff outside mye house on some rusted steel 5 years ago, and it still look like new.
The other sills got the same spa treatment on both sides:
Made a new piece at the bottom of the wheel arch. Dont ask me why i painted it on the outside before welding it in place, I dont know!
The piece in place:
Bottom of the B-pillar was in god shape, so i just sandblasted both sides, painted it with 2K epoxy etc and welded it back in.
A new A-post bottom in place:
All-black. I actually regret using black because i kind of hides all the hard work
Put the door back on to ensure panel gaps. Notice the inner wheel house is now fixed properly. Sadly forgot to take pictures.
Rear fender (quarterpanel?)
Looking like a car again:
Not exactly an original-paint car
This is right about where I am in the process. Will post more soon