Hi
I'm currently restoring a 1988 car,

this is my first attempt at a restoration and my experience has been gained through bodywork books, trial and error and picking the braines of several very knowledgeable people on this forum.

when I got it I knew that there was a fair bit of corrosion evident, but what I did find is that the corrosion works its way from inside out, so what may appear to be a sound piece of sill turns out to be as rotten as a peach under the wire brush attachement on the angle grinder.

Repairs are reasonably straight forwards really, most fabrication can be carried out using a sheet of body steel, some tin snips and a mig welder.

The wheel arches need to be replaced with pre made items, I used Datsun Cherry N12 ones for the back, they need a bit of fettling to fit but the finished product is good.

The sill returns and the panel which goes from behind the back of the wheel arch under the bumper can be fabricated from the afore mentioned sheet steel and smoothed to a good finish.

The front wings are a bit of a problem as there is not much good metal left when it rots out, and they go at the bottom front as well as on the arches them selves.

Probably better to source good second hand ones?
The floor pan can be a problem too.

First job when you get it home is to take up the carpet

(seats out of course) and have a good look around It can be repaired with sheet steel again but there are some profiles on the floor pan which will cause some issues trying to get it to sit correctly.

The pillars are another point to look out for, the door pillar can rot and this needs carefull cutting back and replacement with a similar guage metal, the welded joints have to be butt jointed which can be a problem if you are new to welding.

The profiles for the pillars mean that the replacement has to be spot on.

Expect lots of bolts and screws to shear when you try to take trim off as they themselves corrode badly.

The main problem I have faced is that the existing metal needs grinding back to good stuff, and this can mean that you loose some of the profile.

Make sure you make a cardboard template of each part prior to cutting it away so that you can fabricate a replacment piece more easily.

When you do grind it back, make sure you use a zinc based weld through primer on both the new piece and the existing car bodywork as once it's welded you won't be able to get at it and it will be a prime candidate for corrosion in the future.

I'm 70% finished now, it has taken me a weeks holiday to replace both rear wheel arches and one inner arch, the sill returns and the bits at the back under the bumper, both sills, some work on the driver side A pillar,

they are all smoothed, primed and ready for painting, I have the front wings to do now, I have a fresh passenger side wing which hopefiully I might be picking up this weekend and I'm toying with the idea of repairing the drivers side one but the more I look at it, the more I'm thinking of replacing that side too with a better one.

For the MOT I will need to buy new handbrake cables and free up the rear callipers as they were non operational.

I'm going to get it MOT'd before spraying the top coat as I want to make sure everything is OK welding wise.

Total cost so far for the project.

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£90

+ compressor and mig welder.

(this does not include the front wheel arch)