RUK - Project Recommission 1972 'Dolomite' Auto

[James467]

Rear brake pipes fitted, handbrake adjusted and the prop is back in.





I think I've put the centre carrier back on properly.

[James467]

How to solve the front end rust problem, Alun came to the rescue with a front wing section! I found a front valence in the garage which I can use. I was going to use it on NWL but don't need to now.

Club inner valence repair panel, pattern Rimmers eyebrow which will need some work to fit, and a new headlamp retaining panel.



I'll just need to do some sheet metal work on the lower valence, I may cut it off with a 0.8mm disc, repair it on the bench then refit it. I'll have more room to do the inner valence repair that way.

I'm also now thinking about the best way to graft the wings together, was thinking like this...



I am sure there are people on here with a lot more experience than me on how to do this so feel free to make a suggestion.

[James467]

I'm thinking that the best way to deal with the lower front valence is to drill out the spot welds, cut through the nose and remove it completely then repair it on the bench. I'll be able to treat all of the rust in the inner valence then.

[James467]

And so it begins.....



Lower front valence carefully removed



Eyebrow removed revealing more areas needing work. Half of this will be covered by the inner valence repair so the rest will be fabricated.



The eyebrow on the other side isn't quite so bad but it will need some extensive repairs. I am going to try to remove it and repair it rather than buying a pattern part.



With the lower valence off I can see the extent of the rot in the ends, not as bad as I thought. It's going to be so much easier to repair with it off the car though.





That's it for today

[Mahesh]

When you finish let me know, I can drop my car off for some minor work

[new to this]

James

this has come in handy for me, ill see how you tackle yours,mines as bad but my wings have also rusted on the top,you work quick its a good idea about splitting the lower valance,shame your not nearer to pop over

Dave

[James467]

Thanks Dave!

Collected the reconditioned rad this morning, lookin' good!



Removed the outer front valence section and test fitted the club repair panel.







There's some work that needs to be done before I can fit the panel though, some more rust holes have appeared as well as the upper part of the inner valence which needs fabricating and they need to be fixed first.

I cut the tops of the wings off with a 0.8mm cutting disc so I can see what repair work needed to be done at the bottom corners of the screen.





Nothing too bad on both sides if I am honest plus I can repair it without removing the screen. I have some Cold Front putty which will surround the rubber and protect it all from heat, plus the welder will be at it's lowest setting.

That's it for today, I need to clean my bike as I'm riding tonight! I should get a full weekends welding in as the weather is apparently going to be good so hopefully I'll make some good progress on the front end.

[sprint95m]

Nothing too bad on both sides.

I disagree.
Water will have been running into the channel below the windscreen……..

At the very least I would be removing the instrument panel and glovebox to try and determine if this section is rotten.




Ian.

[James467]

Nothing too bad on both sides.

I disagree.
Water will have been running into the channel below the windscreen……..

At the very least I would be removing the instrument panel and glovebox to try and determine if this section is rotten.

Ian.

The hole on the NS never existed before Steve (Carledo) created it at Stoneleigh, hole on the OS was made by me today! Since then the car has been under cover. Previous to that the car has sat in a dry garage for 20 years.

The instrument panel and glovebox have been out to check the state of the bulkhead already, did that when I got it.

[new to this]

Thanks Dave!

Collected the reconditioned rad this morning, lookin' good!



Removed the outer front valence section and test fitted the club repair panel.





There's some work that needs to be done before I can fit the panel though, some more rust holes have appeared as well as the upper part of the inner valence which needs fabricating and they need to be fixed first.

I cut the tops of the wings off with a 0.8mm cutting disc so I can see what repair work needed to be done at the bottom corners of the screen.





Nothing too bad on both sides if I am honest plus I can repair it without removing the screen. I have some Cold Front putty which will surround the rubber and protect it all from heat, plus the welder will be at it's lowest setting.

That's it for today, I need to clean my bike as I'm riding tonight! I should get a full weekends welding in as the weather is apparently going to be good so hopefully I'll make some good progress on the front end.

James

why have you got a gap at the bottom of the headlamp repair panel, or is it not meant to meet the wing ?

Dave

[James467]

James

why have you got a gap at the bottom of the headlamp repair panel, or is it not meant to meet the wing ?

Dave

No the inner panel doesn't meet the wing, the photo angle doesn't help!

[Matt Cotton]

This is a brilliant thread James and I am following it closely. Good luck with the welding over the weekend.

Matt

[James467]

Thanks Matt

Haven't been able to do as much as I wanted today. First job was to repair a small area of the valence before fitting the club end panel.



Excuse the photo, at this time of the day the sun is in my face!

Next job is to repair the top of the inner valence where the rot was.



Ground the welds back a bit, I could finish them and make it all smooth but this isn't a show car and you arent going to see any of this. It's all smooth inside the engine bay though!



Test fitted the club GRP eyebrow and with a little work it fits very well so I'm going to use them, just have to be very careful when closing in the outer panel, may cut a bit more out.



On to the other side tomorrow.

[Tony Burd]

Nice job.

[James467]

Thanks Tony

The NS was more rotten than I first thought.



The eyebrow was shot and had to be cut out.



I cut the rotten section of the inner valence out and cleaned up the panels with the intention of fabricating a repair piece here.



One repair section fabricated



Test fit on the car, hole's a bit odd but it's difficult to get them perfectly round before they are fitted.



Welded on, welds ground flat holes drilled for various parts!



That means that the inner front valence is now finished.



As you'd expect the club eyebrows fit perfectly.



Last thing to do today is to make a couple of these then I'll tackle the outer panels.