Clementine's Garage
Clementine the Cat
 
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Yellow R4
 
Réparateur d'automobiles

R4 GTL 1985 Restoration

edwin

Enthusiast
Messages
590
Location
Lichfield
A look around the gearbox ....
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Disassembling which makes it easier to clean.
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No words....
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Upper lid and a peek in the gear case.
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The front cover is also excused.
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After a few hours we see again that the lids truly are made from aluminum and the cap of the vent valve is really original blue.
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Next time more progress, for now I have a long weekend holiday. :waving:

A look around the gearbox ....
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Disassembling which makes it easier to clean.
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No words....
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Upper lid and a peek in the gear case.
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The front cover is also excused.
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After a few hours we see again that the lids truly are made from aluminum and the cap of the vent valve is really original blue.
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Next time more progress, for now I have a long weekend holiday. :waving:
 

edwin

Enthusiast
Messages
590
Location
Lichfield
Hi. I am rebuilding a 1985 845cc engine and looking for a good de coke set. Can you advise where to get one. Thanks Edwin
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Hi. I am rebuilding a 1985 845cc engine and looking for a good de coke set. Can you advise where to get one. Thanks Edwin
Hello Edwin, there are various suppliers to obtain decoke sets for engine and gearbox.
Melun retro Passion in France, Der Franzose in Germany or Rquatre in The Netherlands.
There may also be UK resources but that I'm not aware.
Keep up the good work.
Cheers, Joop
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
And on we go with the restoration. Some nice rust pictures will show up further, I know we all love to see those massive rusty bits :D

For the first time my son in law, who's a plasterer, gives a hand on metalworks.
Cutting out the rear safety belt floor stiffener plate.
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This is how it looks from the inside.
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Stiffener plate part as seen from the undersite.
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Preparing to plug weld the new bottom piece onto the stiffener plate.
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This kind of plug weld is different as the bottom part is 1 mm thick and the stiffener plate measures 3 mm thickness. For a good weld penetration power settings on the MIG welder were put to high.

After this it's time to tack the restored piece in place
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And finishing it off with a nice butt weld round and around and don't forget the zincspray.
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The outer supports rear end gets their modification,first I drill a hole so the ends cavity are accessible for the Mike Sander's grease.
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Tacking.
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And finishing all the way round.
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It's time to flip and turn the half restored chassis. Good to see the nice weld penetration on the visible rear parts.
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For moving and turning the chassis I use a simple hand craft tool aka the old famous wheelbarrow.
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And there she is ready to get started on the front chassis repairs.
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As promised the nice detailed rusty bits.
Here we see a former "repair" job on the front left outer support beam... a real botch and bungling job to get a car pass it's MOT...
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Revealing the real problem...some nice hole in the beam...the original material (beam and stiffener plate) has vanished into thin air...
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And how about the front right side?
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Hmmm... even more layers of former bungling work...
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Again revealing the real problem and damage...
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In my opinion those kind of "repair" "craftsman" should be hung, drawn and quartered....:flame:
 
Last edited:

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Continuing this article from the post above.
No rest for the wicked, let's start the front chassis restoration.

Flipping the chassis to get started on attacking the problems.
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Drilling out the old spot welds and removing more patch work.
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And it's always nice to see what we're up against.
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A section of the front right floor has been removed.
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The front outer beam section will be made from scratch including the inner and outer triangular stiffener plates.
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And after taking all kinds of measurements it's time to cut that piece away.
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The piece that will be built from scratch taken out in their sub pieces.
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Let's start.
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Here a good view on the weld penetration.
y4mCAJSO1TtZ2OYiubdr3tQqd2yDv_Jgy0mIdbVz3wiGt1Hx1RjAtB2KEV_GpBzK9EF7zqg_b203SWcv8hoO7U3aer9Mfe7jTgavfdUQmQ8pL1DB2QUJlWTmL4rX4yg9tIAHNx2oTzL5jkKAf5R1Lc44OPXTkaXPTS35qmldHvOxeHBbboZ4EXbWefnpaxfQWrBqvWUgIgmYtg0dc_WPPsl6Q


y4mMBDE-L1hyiE06INxcR07CS8prk4W43QyJHdLgSFFLBB5KNNIDdxp_ONV7Oh1Cy49mub4itInYFNJ9QLeWVBBGBduH3F1PWuWJwuKLmmsN8BRyEVvif16-5SQEmUlUZ47QvM6Z2QohiNsRndYCRvxEXFKYdpN2PRPNzxHxd-sirXQRNlz-WOP4R2lwLth1vUOwW1Bm86kpK77FeVy4G11gA


y4mkhETx3__XKzhfPamfpiZmW3trDs9il3-czCiBq3Uje4pQHnouGFFq0SXnLnm_EUxgXQGoseawjdFLdPrgT69hGlrylUKAhBBoAXcv5crYO_8UphyZZ4lLs802dnDjwNyg59S5W63VrBsWQNSEOQeGfGObY_7fzEhNn-1hB_9v0QMd_GHZ76n-RNQa7pRq25gACkoxLW84pKim9zjF7u9wA


That's it for now more to come next time.
Cheers :drunk:
 
Last edited:

Jurjenz

Enthusiast
Messages
447
Location
Groningen, Netherlands
O wow, that's some serious work you're up to, but keep it up and keep your Cebora & cold beers close! :welder::drunk:

WP_20160102_17_01_19_Pro.jpg
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
O wow, that's some serious work you're up to, but keep it up and keep your Cebora & cold beers close! :welder::drunk:

View attachment 20262
Hi Jurjen,
thanks I know but you had almost the same challenge and amount of work accordingto your photo's a while ago. I assume the cold beer is to cool the metal after welding? :D
Question: What's the progress on the spray booth on your location?
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
In between all the front chassis welding there's more to do such as work on the front suspension.

Here the removal of a very stubborn inplace well-rusted upper ball joint.
y4mOo_weU7pEvAUUdH7aBwsRp40Bvaj8l98C8HN0t0GKyX_GQ-PTQjgelNeY9MiDKgt36nd4LG9WhSCE5whe_mltaob8fAzS7-o-aDKvO3Zvp-Fg7aZZ-YPzZ62JY-06JnGiqOq33DLVsVOr7dtcYR0yqr2hp3crKZFq1rhTUMMoxT5SP_PaHIXEka5MRqPPyYN4jH-ye_7d-gMeUKd_2MaTQ


With the help of WD-40, some time and some gentle motivation from a hammer, the piece came free.
y4mrAVjDw9v6NKDI5sqoBNe6epayV4ia6JD_pP2pTyS8vUcfxB9EqQUOqApfkBX84vkRYQXcT1i-U2H1_6ok9lVYddJiOL7rF0DXTvY2P9VzIR8vnBgnl5aZfxhRL3R3DWj4thAjSFFLZHsgdfE0PuWdGx7np5gdQ7_Yp2RmR7KO-zCjqZ4lS1-fr8e0olaoUNVo4vrfTSkFt5h0yMAiScOIQ


After 30+ years of service it's time to replace all the silent-blocs from the front upper and lower wishbones.

First I tried the easiest handson approach to remove the lower wishbone silent-bloc...
y4mSLBAmn6Sdsqg-_4yuDkkEALOJqQ2G3wX4HvtuVFv6NesMQ5EE2GbR7c98xQGRcUVyhkXlzPt6_N4A7ox1TXtIQnTAhZ3M-2a1XktpcAyNpnLf5MWnqsLqQN6Cm5zYI87C9vEwwI_zPlsSF_E429H-btVwDyRLnyhlxqHeHf0yCwp6RHnj5um0JcGco3jac0Y9WYR0_ioQIbXyqUc2UNa7g


But it wouldn't budge so I switched to the hard way, drilling out the inner bush.
y4mr-flYO-mvpn_9O7dSXcpMghW4RLgB-KTOVF_E8tYRxuZ7N1i2nLrxd1soahCEIIigKeLqOZdUyYgJBoDlhb4meZ71coXhlEC7hFrEfXaBnajIHH79lgpHrr-FjApZkTgx0b9CamrJkKnehjrMCACE3x6kdDxHyJWJrGnpKOgvri3q3knCA1IIOlXijQOtq26B3BCtW9_vgpLA2iDdlbbCQ


Weakening the outer bush...
y4mNpSxCVSxC0sPL3oIDRCWvMC21S6y1lNBQOEsgwjRbuhKlQjE3jY8INUAQdqkJrUREN_tL2R5w2XSyPW-EwSB8ViieJ2hkfp8BpqQVNMzAvhTs4JviZ4yvmTiS8lvtKzeZkQ97kLhpKlv2iSocv8w656b9TqdCIepZydPAA7G7_z9pHuiQFEaBqy11yaTeqVXYrDZtxC8-C09D1wzRfHrHQ


Then a while of tapping, hammering etc. and the bush can be removed, it was well rusted in it's place.
y4m4yG-mWkp2nL0NIf6XrwwFlX7eEwP6qZ3Lk5wzciyw0d-_vhLJQIR4p-si4bzCQP25H3PclThr6fCWgkiX5jp9il-2isnG7rGqsU9B3zlEKuhTYw5TeMBQHI4PrCQPGFlAcwvi6Mw9vhYyz8E9XrfuGqETTq4FuHMP2iEjYtSqp1Vxuzkc9tcu2ZcHnrgMbCHfrsI880Xnj10zZbiE28l9A


And after some time the silent-blocs from the upper wishbone are also removed.
y4mPq4_rvki_8ahLlXncXWX9yAMdOYe_OU43ggvipJnVXF4gd9mZcuqUVGf87wSStu312SvB3cBIsVhZay-8rkCrRY_ivGtpLjAejxHUjCiTWq-lUdse6aYVRBs2NIOY0Kk_Q9SY0qiP2RadjILus_ZsYC9013t-2MPM2IP7Cu6rXfnyKEvaVlIe3pGq1wfqqh0Im2PSbLWdq8R16ouxStdxQ


The new silent-blocs and some .tools.
y4mDcE6w6ehcLUAIlUbh_MAqUbTQn5ze148U_wk9I21hi6Mb8g45-BFnbJXQhxWVy5wh-KtkjQlSGBeQDtaT4uR1NJpwKUgd81Eqee3vhN27k9n1grYb_Ug8MAbB0E63gccVw2t61afV-nK9N9s5BcbtAHlpbvW7linjJu3FdmbvIjut1wgSeG20QVz7dr9Dyi8n1X21nMW7a-lzJFAdzL-oQ


Pressing the silent-blocs in their places...
y4mNveOyxZLgHUeNjiaS2B2nd5DyXr81wgkHQVRNOAp1kTB5Z4uzW4adHPduxUAU4ZbYg98mq9lV472kpxcI-GBCWCHdFP44t8RtC902yLXm6g3ZbxyzUd81PLiMOJ5zHpsGfEbWDWydUfyJ6ILCnceITVYAHSTZalteJLsiQhAhPV4l1xbbaB1YexcjfmFeES9DWzBkSA-wENrubW6N5tOCQ


y4m0IbkpJPurNlDm0C9DkSIstjreuBqvjiKrpNIY18xagCoDer6eoBKg79j2zE8pQhKGI_N9J6qpFwWxMbHHLOQacTPAMj-QXXRcQq40im7wT3ZBDN5fH03PmNiEqcKdm1VTGKxmfPd8ED1raQznOZNuD_eBnscb0LIRh4aYFByZ004v99W7g3pS2NhFb6ryW_KSm--HcFjLED3EZyYokwONw


y4mDFj3-MPP53dgHv3lzeRF7lZsy0FgUceG5RU4eTJp19hWHxSOBE8H41Xg8SxGy3Nf59nbEuqSBwKPFscd6CmFOnEgMzvkDPkdgf-7C_GcugmLPRbh50sAMSUpS5ZxGwOqbmC9qOPFok7KhZ3TNC5MNBUG5I3aOKzTt6bQF2s-38bkyWn8kOoSDCVQZ3P1gP3IEE8Ccm4lgTTSJOPESlefFQ


y4mjnrU2t95tU6W9G9hGT-rSLgc4TffOjH7uIYa3Q8vI399E9mqJk1gP1R-LYhGCcBESefRijz3IRTFAYmyJ16YgLKImt_7k-pn1Yfg1mgRIwvTZk7-cd3zaCcrAHThdfBvFdlVEMfuL6rOGLIrt-slfxM9H88Nwde54VE3N35v5_OgYY_IAlSwzbFKuDPu6JvLKprrEQ5FxBykwpi41H6kMQ


And again a job well done, I suppose :D

Next time the welding progress on the right front corner,
Cheers, Joop
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
As promised hereby the chassis progress on the right front corner.

Creating the inner and outer stiffener triangles.
y4mwhZbVTiaEaDpi3t39GH9iV-3YO9gmjC0Vx_jNVAiu-oVga5Yrrcz1AjvhdeOcjTnKc5jbq_JJ_dKZu6dh0NYoSV0oOuVtp0k6owYksVJveEsBcnutf0kiMNmMKoYax8TBGzcb-0b0j2U4tMjQ2vycYIxeZ27AwGd_xH09LlQfYiFVARQGUEuHAjxk_RNsRYs2vEmtu9oczlfw_2_Yz6H7Q


Rescuing and old part e.g. transplanting again an old bit.
y4mtPMCoVl_vKwbquKcCpgyRPVIz9Is-vYHpOJuwOOywXPtD1O_MnnxZenSWr6F-ZoB3bLmJ3GpiPs64YFoj2_JvzCJfUznwyKA56cXYxs4q0Aeypgt7Cjvind4yVgl5E3YIzObzySfnuZuiuqcXqxI-vWa6phguYxnCeapKIXNqzYYeBdwNyiZpothCr6oO_scuTPdnMG3Hr0SqRUey25NZg


The jack thingy (or how does one call that piece) wasn't salvageable so it had to be made from scratch using 2mm sheet metal.
y4mGKSUiHnK_lXfEPRjRVY4FyjhGoiV39O1IajGG8_gjETGm8dgzC-b-XC7j8WYRR4goHqyN3o5SJ3dcfz2flxcAfygSgN3lLHYkrM0zf3Y2zCdlJpvTOSeNlKXfjZ-WmhxFdhDBBxeB01dg2o795RXP_WCivC8STnKfCZoyoyUGod0NkSNYjQG8SL-xQ8ob87hl88Q5aVqZmGPKr8KpNmCbg


Ready to weld the inner stiffener triangle.
y4m1gj3MOr5xNF6gsqCngz1zzO8uc5T4x6J37okYFgIARitt6DCBCde_iwA8ZggoC2BqmrsCuWoz15epWUr_meacYD6jj-Mz2t8sNqQfQjlHTzHksgF4gnA7gn0QRdy0ExZBL6N27MxBFGj5AUSYm2FBG-gjURLh5JZnYjBYSNKprm7HiucLW4a4khwE9MetCPPMzRT4MLVVlpakJprkrxHZQ


And done.
y4myenYq46_2Iki3BRE49MKiWtyZM1mUuUWk-WIY595EBbHUr6r1TkVa41Mq0kESeEHZOuvDSBWPK55_HbONtWDyE6dYi_mXwrsoYwf_-eQJjCDkunUTJSnBR6lpc-wDYilnUegRhhaOVxiiP_knWUXYZMpGIVix8XeIKzqXZc9mI_pi-0k0GNBK675jhPigf_bD5aBFmo04aoqyftwTM6eew


And miraculously the outer stiffener triangle also done.
y4mvpFtrQLxc3rfq8UaSqjJ7vphHh3wjb4M3zp2v2L9qAkkhZyAz47zl-Gu0ChfRdzN-f9pl5SVDkVXOq3EKXW9HBHL7p8GbNiddT7CQdZDoNBBWVvi-1QGyCLWOcQ4S8WceNGYpDhNIpXvu4N_ba2p83btRJiO1-89pFM5_yVyUbfLs-26IG-5QxOdl3LVyDfQ0iIhAqJVKnlOcd9k7x8PZg


Here some rusty strips are refreshed by new steel,
y4mefcZ7Xql_Kj19NCLyb3wFGnfl79xmR8HWxCIsrh5stjt7Ue9UymBuHKcPh2NbJxI-X5pOuJrCFZR6rwATmSg0s2uVjjIKk5K31fd91VnxTCFaYNC5ncWFtL0RXTSQi23toog5aFiDvEg3kdxXQO7bs7sD7cZqMQk_6XszsKfi_s0XmBPSy_CvuC8RnT3KkMyViOWngVS9Sj61SM88TdmaA


The new created piece for the right front beam, tag welded in its place.
y4m2fXZaSddiMYb-DvEUtU6sFl_Pwbnrife7OBsIM9Za95xNQoYtAO3rPE5-4FOiOGCVlTM1ewTOKAuAJvaswiEr09rS0hS5P4RCkTpRr5nJ_pKRaZnG-5yPt79f8D0_bG9v8bqlByG-smxpUHxte4bEeWucqX7fiz-XUT4nr8n1GDwCdvKDxrCizkyrVHcMWi2jxjtugdClQr4iE9QOZcoEg


Meanwhile new parts arrived and you all know what this means....more and even more work ;)
y4mBiBNhDeaJKAP0AlD2FOGwWQosks_uaXSMrVIuPaqUT5zEkcl04SUeZp1IFVSv6O2ShJtupGNWLc1nrHTWlIowrfmC_Cfjghe6pJsv8xkJo41z0vMbWJPqM6yL55z94cTA6fKpPUA8tJ_eFDT5bvsoBFJAfQRF8JxAXih-hahovwbVhVhbfjj6pDZS8Asy0J7rORH0KgJ8cHXSMdp4pHkeA


Creating a new piece to weld the beam to the inside front cross beam.
y4mcFx-9dHA8LH1z3HS7qPVFQvPkHNMecsWRggredr1xg5fNL04Ut5Fd8CvXnFTWXKdunRXmOfOi52RVWjP89z8p9BHY963jJ5SMJ1-gfVxZ8RdlznXBZwWgWkLob2zL1YjKc7Noqj8Go49Omnz6eas0QEIatU3PKw8_djYTMsGxVcAxKxGZey69sOnTWGa2_S-A8ezKWnABbomPsRL6vku_g


y4m_e1t9DcvNzOSpkySKzB9DDluBIqX7_fo2HcL-0VRpsK0OxdqEpc5yCdvXJv3I-zJWZ4ALFeXHrRxR9rAk5TPJ1hFOerVwCcKRyFNfGTyvoRQ2_ZBo6-2dQDWfrw1WqFmamqTsEb13AIB_STjdZZDD53rB9Il7c99ttsSkMHf2R8R3oc6LrplkOyr4kjDJsN2HFqTITzw2KL31evZBs4DRw


And here it has to fit-
y4m_-bIuCihYerujFbrxnYUEH_HctGX-Faosbs1ysfEoRYjzWU-71K_CZ0LLdT0dS7AOWx9QnozUK2lm_zffJWwrM7hc0ytZqKnsShcNbqrtAdG8dqbyuAlmxVa6HsvcL0QmdEz5KhQNx7rZX2kgBqCqK3AVHTU6sHRYErqIGhwIw8QPDC5Xo_lNU9nm3gxrq73Rti5vJ0KAc25y6cJPIoyoQ


And welded...pfffff the grinding will be done when I flip the chassis because working, welding and grinding in impossible places and positions is something for youngsters :p
y4mFMZF_HGDtIG_re3U-w_nrKR89ddF3N7vRx9URFOhfGOFNc59dzL7SlHzxNg8AUA1vWBGonHI-b7-mveTy9NDvWvLZRnNZ2oYo9I0yFP_SBo452nO93hOkYeS60StXYUd7CXgF4gM-5YmN079ZiYarP5ooPbcYhnPaBtNC9Ip1ez2dJDC_tmkRMlgtrgztprnGVKbjm-XM6T3U0gn-9VZ3g


Creating the outside right front repair piece.
y4mXEu3mOa2izLfdiT-OJlY-kYZo_MdBihVbXwmLWyECHxmgsJ5SWepX0Za3NWUgMLMreowRmxJl5mdS2jut-DADh-ONCllz6Bewx1XZNrWWyhHDqAiHQmhAb5Req5DGBY76YD9i0CCAAXSoHaPV9hiMKnuQpWm7WfdtcjQcILFuIpBccp2d_7UsZC_efHXf_6Bs93mSI-k8Rp-KX6AZCHahQ


y4mqmAmXUL1GYu-eWLoW7gAODoSAivsSo6nd-ZKKJR1by0ME8ni4yflo4RQ9I_vsISrVN0gaKoeWCpGnNk8_QoYfb0fzs6PhAY-uW_7SWyOzB6xWTztwkLEveDZkJlvGIxAGqDAy2rsOPRFn40S-j2cqVZ2mwb_uxtJXddJf9INIx9iQAVm0lOWPBuFxzn9XmPT0EOlb6qkeGmSYH5EGOa9DA


And more shinny new metal, cleaning up a bit and ready to start on the front left corner.
y4m28_ZZSe4ZsQz8c95hSXXSsREM0uFRJFiNVHbVrn5TX6RWqqdLp9oxgDLvcWbA7IkGqZcWdA01_J0xkxdO9uYCVMRTifjE3eVGCgyoMkOVNylrDlPRGghXr7ZzVv25JAI_TEDwmzBsAhqNnVjhbTLnlxUSfo-tq1prnbN4HjxYAovC3BhZJKrePcnfzw1FvNDTGaJXhVMTwqRKA9pmtHccA



Time to start on the front left corner and it is more challenging because the front left chassis beam also affected by the famous R4 rust....

Here an idea what one can expect and what I'm up against :)
y4mLLzYXvaNsMoNdGelkf5xdxgqr-u4B7evdhUsXu6kjPZz1c8qz7P60oeFQXCynFcEPUBecz7bm8UhqOzLGeA623lfgZKqHoVrKP3pQfdqN6qXayT-9QJ2ei6wbymwKrfD0w5dWrlv17qzKM46DvocSk8OM2oIMgWi4Bg74H-97zVGrW2zWr_06ZOdb9a_GjcDWadMqicXR6iP9GSuW4MHMA


Bye for now :waving:
Cheers, Joop
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Great work! Thanks for posting your progress :)
Thanks jjad,
The trigger for this full restoration begins in 2015. During MOT they noticed some small rusty holes in the front beam.
y4mPafqXtIlG5Qj5y7yfRN16B11aSXNA2iSvuq26YBavduLdyqiXBVRIWQi7yly4YsiFeAZCXr_2z9gN7a9V47jg4ZVfRsWNJlGJmJSJ_VRbBjeTMHmoGz4lGwsDQcdBm8NQyWOT7SjMb1XyrzDNdqVkYiK0BfNx73PJ0Sc9X4vGai3682d62_dQdVlBwWNtqU2b_afdl_9W19mFsZZkib2nQ


When there is one rusty spot there should be more, they never come alone :D
What can one expect as the dismantling starts? More and even more rusty "bits" :laughing:
It's good to post the progress on this great forum so more people can see how to deal with repairs.
Cheers, Joop
 

Jurjenz

Enthusiast
Messages
447
Location
Groningen, Netherlands
Ha Joop, also you should be thanked for posting & sharing your progress. Fantastic restoration this far! Are you going the replace the front part?
 

petak

Enthusiast
Messages
1,756
Location
Vodice, Croatia
So far so good! :D

I'm kidding :laughing:

What you are doing is unbelievable.

I am really interested to see what you will do with front crossmembers. One that engine sits on.

Also interested what you will use to protect metal from rusting again.
Especially on those places where two plates are welded together and from inside chassis crossmembers


When i look your picture, progress and how "easy you are doing it" almost thinking of doing it again one another project car... I said almost ;)
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Ha Joop, also you should be thanked for posting & sharing your progress. Fantastic restoration this far! Are you going the replace the front part?
Hey Jurjen, you've done the same, posting and sharing your progress and sometimes I still take a peek at your monster job. :D
The front beam will be replaced but the front chassis beam will be restored, and that will take some time....pffff.
I got some inspiration from Malcolm's front chassis repair he did the bottom side and it's a nice tutorial.
Mine front chassis beam has to be repaired at the top and hopefully it will be a tutorial for others as well as myself ;)
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
So far so good! :D

I'm kidding :laughing:

What you are doing is unbelievable.

I am really interested to see what you will do with front crossmembers. One that engine sits on.

Also interested what you will use to protect metal from rusting again.
Especially on those places where two plates are welded together and from inside chassis crossmembers


When i look your picture, progress and how "easy you are doing it" almost thinking of doing it again one another project car... I said almost ;)
Hello petak,
First I'm still wondering if your forum name is your real name.
And yes, you are right "still so far so good" :whistle: as I remember you did also an unbelievable job yourself :clapping:

The front chassis beam (aka front crossmember) will be restored, as I wrote to Jurjen I got some inspiration from Malcolm's front chassis repair he did the bottom side and it's a nice tutorial. Mine front chassis beam has to be repaired at the top and hopefully it will be a tutorial for others as well as myself ;)
Not only the engine sits there, it's also structural for the complete front suspension and steering

As I weld two pieces of sheet metal, I use a weld-thru primer either a zinc-based or an inox (stainless steel) based, depending on the application.
At the end I always first apply a zinc spray inside and outside and at the very end all the insides (cavities) will be treated with Mike Sander's grease.

And all the so called drain holes (which are actually nothing other than water magnets) actually atracks more and more water between the several layers of sheet metal or cavities, all those holes will be closed.
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Front Left Chassis Beam repair part 1

Disassembling to see what whe're up against. :o

At some point in this R4's past again patch over patch have been applied to pass MOT.
y4mCUNdODP4dtSieffW9BWSB-JaN_BrJksCYnRFUcpSIINxP7R3bYnoLNz7HPhJbDsqfKIQOW0FHstMJtxvFvUwh1g-szvNyd0TzjV9UjFnzzAnY97beMN2CfJ1YDf8yKQp2QCrYaz04SbCWpc_96wv2--Nm-gUqb9EFwHt2kMrnd2Z48tvxyvifdKYaUrXMrM6Vf2U4ORbo5wrNlIVcsK-3Q


Underneath such a terrible fix the worst is to be expected.
So lets grab a 1mm cutting disc and remove a piece of the floor panel and flip it over.
(Needless to say to drill out the spot welds first.)
y4mGcT2mClpkiwc6GZW8YEUXBEjwnwGjP6xzl1tVoGeEFQ84sgpcJOXmpRAmkBLsLWewuIG-vWESuOf6cFmvJxnmkm3C_5oXo5WotslIOF2bMUayYQdZQ6cs0n2K0KrLzXTD0Z6KZLUrstcVN_qguk4wB_W2i-QDNmKYRb7pFLBnUO71NXYMnd9r0XlQMFi7VVAf67EQ7Gv8D8Kuy9xJcdSBQ


Fortunately I'm a lucky guy to see what I'm up against, a nice gap (or echo pit) in the bottom of the chassis beam.

A small peek through the gap at the inside.
y4mebTeY7_5aOR_h-_6PIXQNVWXgmamG3jZMky0ScuvYGX64G0WqORWzrVpxwp0SE9o7AxJtpfKdYA6fm4BGoAF7NAu8Lk-gS6xmlPYW9x97DpmdxlGlmJrDXeWvfSt4WND8c6YD158h52quN-CBHF8zRieotE1BU0BJm0B30m-vQMH-Tm0vKez17Cv918i9no7Of83ZCUAxFA_1tShCbIwDw


The left corner isn't that bad at all, so I must be really Lucky this time ;)
y4mcRrtnr2AT43M32AwkzKbHtkalzsgNl28bdhjIE-KsocUwRY-XyL1B0AbJ1cCNIR2Sp7VThE3jrFS-VoF8a_qxUN2mAjN98rwvFgc25y64U4FHxG1XGqcwmScc1mbBMTMM6ewo5dT4LFhHi5ztuocpggidh-2R-GBMNCfp8fgrzMtS9JOL-pJAltfR7v_nHuMf7RY9crIrXIvZusL9fm0cw


This inside triangle is in good shape and state so I leave it.
y4mZohEUHYOme_LRzi4lb6SGerOiuxswiDBsm8UG25bk2Ir5EAjtq3BGc-cmzjEwb9JvztOiHNV_49ttGMCUfEf_Qf4k-IqMn0XG88qv8xev6aHtZ5zcg853fbXK8scebnziXaQnluv81O0hNpukIjWywWoyj-93QiyMINWovhJGiyCXkNHF6Nk7X5z5tEuX4m3yKOOJ0MhFcDENx_PJIf76A


Only a piece of the left front corner has to be restored, the splash plate is removed for better access to the front chassis beam.
y4mKPGk4ZkgCOWUJMy74tLaK_mbiYaXDbBfj8dlKaqYiiAWjF2-3AACw9N1_uVhuwV1IjDCZoIlCDfSR8Wxg-ohgPHFDn_53_rBWpWGezCQ7xRPDo3vygdaOI6laAyPkojZG-eezfRoD5YMN1nuwOE-W46MVbsY7rAZrlvtJ_SGm4M_N-GNkUTTjCc4kZo6mRBoAU6TNxNRi1CGoUi4gcsUiA


Continue with the precise removal of sheet metal to see how far it is affected.
The front chassis beam is a nice construction of multiple layers which is better described as French pastry dough and in combination with rust we get a croissant....
y4mrb2JFKINAo39foMfEGG-a_EPE41xKhAb07F44uBGLmtgzAiJe2EjPomddspwByS84Hlvdj5yyl4U_yX8TBMPDodl36zrbuEkBPiBqh40pVF_1WIxrVq1yu1KAdEY8rx6XEh1ScANNUs7tCir3NTegFue9G9v2NdRzgy9IWn6E_LwtjFTR_CafaagrJ_ulexcewtbYuIfzEfGUnQedpMwXA


Here I flipped the chassis.
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The steering gear support is also affected
y4mkdzEsXVG8rXAbAc940MXbGnnWDOoNqkWpWa7Bf-KyDqAwxzjOkbKWtiWSGq-nFGDx2gGjzINBgxxgX9H0sW-kWl3JY_8S0A6_-i7Jif2_sbmyWal-kpSprC9p-08CpFPr4EBmu5ezPEIKjgWy3GuwZrOrs-VDZMLHBBB_4OwC8XSnv0v6MynsaR1MOc5Pc9NpWBYFHdsJd8Ws4UprgnZMw


Drilling out the spot welds that keep the inside part in its place.
y4mW6H93TlDT0tJW4uDF1xNpuDLhwnFZiepvjnKUB2I6lW3lqOu0Egz_3NdngABojngM5wfvNy7Yus9jJ0zG9vOo8Jw1nDTlajmsDOHQ8plFvvu6Uh3cJ1_ne2AjingMWcZzPw_6y5Jm_Yy0qVdDl1RzEq7BztbzRyKJDz4PqYqMjayMpCSu8FxSxoJGHkCSgJ88EwYKd1oHFtOPZrmReMk7A


The inside piece is out and will be rebuild.
y4mEASVEaorh0zkF-gDOQBhY9l6j_kp5tbnhi7BF8SA9AJ7UE-IX1UgehK6hRTSG6kCDYFp2Mr0OJPJQrLqOy5mEZ3j7s6vVVxzdk1lXL94tAUAR1vI1FvIBnl--oP1hzdrVjtdqMAHinJ2xTHPubfgm0F71j7IG8F_I64_bi7QeAIXfGtd1h9SrGRBSGFX0375VyifO80hPMlsnSJYo3c6Tw


And a look (top to bottom) at the front chassis beam's inside...
y4mb6hYUjfJ3LtpJCikg66dx-zcjjubR3DrwDQ1mKgduV0zgZz4tc7X8f-JbsNE6nTgq_q2PW6yaq-VevqAfNyXKdoV_cGnUU3qH2pKkxBOntxqshSp--XTXtTvfwWihWVyfuj3M3wCWZLR1wGpCQXl1faI1FiBnhXHXmAwfFmTA_Jzc8I8m4peTdoF8wTgWK43N_zgP85RD8ZnAzE5-9dM2A


The front beam is also removed revealing more rust. The so called Napoleons head looks worse than it is.
y4makbLRez_YOSQmEql-vlvVnm56hFnu_EjGx16tCYqJXX-fMqnTfdtmGjl_kmvYUl_Hv_tllmC7BGLr0BkDwnuknNK4-wMVcByKrE400N-c83HVZ3jWuahs6ysBgZrnypYPlBUhUD6KV5ElnepZshDPWn84QjbZnfdpCNCl2onvM1TnFBbSTKreIgALSZN15SpMTEpMl8TDAH0DUGJ_ENKOg


y4mwyqzDY3I3y3eeQhoJKBQ33aQkNKnU9eBuz6arYhQQVWtfS9PZ7BDCFonTuiihfPJffNei9mMo6UiOt3m287kLEtwcqvws37Q2YG_X5Msjux1WGwmOa_95eFmhvZxCIOvz6IFH9nbaJlCfIXLTnqzanQImGD9Usx4UcSdKJxQIgRFcI7VFGXKGl2AoPUOh8uT3TloXbUoQNr-n6OU-XvE5w


That's it for the disassembling part for now.

Meanwhile I'm allready busy with the rebuild of the various pieces but those will be revealed next time.
Cheers :waving:
 
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