Ok so I thought I’d start a build thread on an already built car if that makes sense.
Maybe more of a “how to” as well as a build thread.
Most of you know this car as @FrAsErTaG’s car.
So I started by wanting to change the radiator support panel as it was involved in a minor bingle.
Started with the car like this (semi stripped after a clutch change)
I had to drill the spot welds that are made by factory first with 1/8th drill bit as a pilot hole for my 8mm I used to completely drill through the top layer which intern frees up the panel from the body. Hopefully the pictures make this make sense.
Once the small pilot holes are drilled then run the larger drill through the holes but try not to go all the way through. The best way to know your all good is to try and see thin black rings in the drill hole like cracks which is actually the separation of the 2 panels. Like this
After some help from a cold chisel (plain screw driver is fine) you should end up with this
Then take a perfectly good cuore like the one below
And start again but remember that you want to preserve the panels you are removing off the perfect front. Try not to drill the crap out of them or bend the shit out of them when prying them off.
Now take the new/straighter front end pieces to the car and fit them up and try and use some reference points to line up the panels in their correct position. I like to use paint lines or the drilled spot weld marks as per the original. Clamp them onto place
Once you have all of your mind up marks where you want them start to plug world the holes up. I use a mig welder for this.
After I finished welding the headlight pocket on then put the front of the rail back together as the picture shows
Also a good idea is to put panels on that will help you to line up your job for instance in this next photo you can see I put the radiator support panel back on to make sure my measurements were good and fitment will be good when I’m finished. It is not pictured but I also set the guard up as well to make sure the holes will locate when I put them on.
I know in most cases it is a big no no but when you have finished dress the welds up with a grinder to make sure they don’t look like lumpy ugly welds.
Also run some paint over the fresh grind and weld front and back to make sure they do not rust.
The reason why I used grey rust guard on mine is because I am going to paint the panels a different colour down the track so not too fussed for now mainly for preservation.
As you can see the bonnet latch lined up perfectly.
I also managed to get some bonnet adjusters made up that line up perfectly with the Gino bonnet. I left the old ones there for reference.
Here’s a pic of my afternoons work all done.
It took me about 2 1/2 hours but may take longer if you have never attempted this before.
It’s not a real hard job but again if you are not confident I would not try it.
Please think about this before you attempt it without any sort of welding experience. The integrity of the welds are important even though the panels are not so structural. I would not like somebody to try this and get into an accident and become injured or set airbags off unnecessarily. Again please be careful if you have never tried this before.
hope this helps people who want to try this but we’re unsure of the procedure.
I tried to take as many photos as possible but as usual I’ve just rushed through things and forgot occasionally.