wurlycorner's '91 BA4 4WS SE Auto - body build

Post by **4thgenphil** » Thu Jun 25, 2015 12:42 am

I'm there aswell. Should have some space,the cars currently full of wheels and tyres

bennyboy · Post by **bennyboy** » Thu Jun 25, 2015 9:12 am

Really sorry @Donald, for reasons I won't bore you with I totally forgot

I'll take them along and hopefully get them to @wurlycorner or @4thgenphil, you can chuck me something when you have them.

89 UKDM BA4 4WS (resto job!) · Post by **wurlycorner** » Fri Jul 10, 2015 9:10 pm

89 UKDM BA4 4WS (resto job!) · Post by **wurlycorner** » Sat Oct 17, 2015 6:12 pm

Time to update with some of the stuff that has been (slowly) happening with this, since it eventually came back from the bodyshop (very pic heavy);

Lisa worked hard cleaning up all this for me;

Spick and span ready to be re-fitted (except for one mudflap that was MIA at the time, currently sat in the hall at home

)

I still need to sort out the annoying niggly things like this, where someone hasn't put things back together properly before (pics before the cleaning took place);

Should be assembled like this;

Brand new rear bumper bar arrived from the philipinnes (had already paid before finding a brand new one locally);

Unwrapping shiny stuff is good

But being new doesn't mean it's perfect

;

Sorted

The rear bumper bar on 3g's is a nightmare for catching crap and corroding (much worse than on 4g's) so although it's shiny with paint, more protection is needed to keep this one mint. Cue several coats of dinitrol all over;

Which meant I could wrap up the other brand new spare rear bar I had obtained, in the original packaging

89 UKDM BA4 4WS (resto job!) · Post by **wurlycorner** » Sat Oct 17, 2015 6:18 pm

I've not managed to track down a rear spoiler LED bar

so the in-fill will be going back in.
Originally it had no gaskets, just fitted as plastic-plastic, so I made up some gasket from sticky-backed ccf;

Manky old screws (left one) replaced with better condition shiny ones, for anality

;

Ready to refit;

Also needed to make up some new gaskets for the mounting points, from the same ccf;

I had carefully removed this securing clip from the old bootlid without breaking, so now to refit;

(no pics of the spoiler actually fitted though

89 UKDM BA4 4WS (resto job!) · Post by **wurlycorner** » Sat Oct 17, 2015 6:44 pm

Now, I had stripped out pretty much all the interior for the paint shop (more than was probably strictly necessary) with the deliberate aim of getting into all the cavities for rust proofing, having been properly dried out in the paint oven.

So, the sum total of the

rust on this car is...:
Inside the drivers rear quarter at the bottom;

Whereas from the boot area, all is sweet;

Back inside the quarter, after some vacuuming and scraping (access is NOT easy);

And after treating;

And then cleaning;

And dinitrol cavity wax;

Looks messy, but that's just how it comes out of the gun and the important bit is that it's properly got in everywhere

Passenger side quarter at the bottom;

Passenger side looking back over the arch (all clear and drivers side was the same

);

Passenger side from the boot;

Not so neat under the fuel filler, but no actual problems;

After scraping/vacuum/treating;

Then after dinitrol cavity wax;

89 UKDM BA4 4WS (resto job!) · Post by **wurlycorner** » Sat Oct 17, 2015 6:58 pm

So, from all that we can conclude that the car is amazingly rust-free

and hopefully those bits should stay that way now...

The original factory applied seam sealant works absolutely perfectly, where it's applied - the problem is that they didn't get it into some of the places that matter the most! They stopped short of running it down in the quarter panels properly and I'm not convinced the panels were weld-through primed first

However, I then went and studied the car-b-cue (having a car cut in half is useful here!

)...
This is looking back into the passengers side sill;

You can see there are 3 cavities. It is the outer cavity that you can see down into from inside the rear quarter panels. You can't see into the other 2 cavities.

A similar view down the drivers side;

What you can see, is that the corrosion is actually worse in the 2 cavities you can't see/get into

And along the bottom of the outer cavity, in the seam running along towards the front of the car;

Some similar views from the passenger side on the car-b-cue and all is the same...;

After viewing that, I got the extension nozzle hose thingy for the schutz gun and worked that into the centre cavity of the 3 (you can get to that via the outer cavity by fumbling around);

I'll need to drill some holes from the inner sill, underneath the car, in order to get into the last cavity (and then re-plug them again after treating).

haRRibo929 · Post by **haRRibo929** » Sat Oct 17, 2015 7:29 pm

good job

she will be beautiful

mercutio · Post by **mercutio** » Sat Oct 17, 2015 8:48 pm

great work Wurly and Lisa

wont the 4g rear brake light bar fit???

Post by **Vtecmec** » Sat Oct 17, 2015 9:07 pm

Brilliant work both Iain and Lisa.

if you need a hand with putting it back together, just let me know.

Lude Generation

wurlycorner's '91 BA4 4WS SE Auto - body build

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Re: wurlycorner's '91 BA4 4WS SE Auto - body build

Re: wurlycorner's '91 BA4 4WS SE Auto - body build

Re: wurlycorner's '91 BA4 4WS SE Auto - body build

Re: wurlycorner's '91 BA4 4WS SE Auto - body build