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My Attempt at a metal wide body build

russmw said:
Totally admire your determination and “give it a go” attitude especially after giving body work/painting a try and failed horrendously (bringing dead paint back to life, electric, mechanics and interior stuff I’m good with but not bodywork).

Looking forward to seeing more updates
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Thanks stay tuned it will be a good 12months work
 
Amazing work - maybe you should fit some turbo fans on the wheels - would look proper cool with the wider arches too....
 
I'm using early offset Fuchs alloys 17" same size as standard car but the early offset pushes them out extra 23mm or so
 
Problem with the rubberised undercoating when it’s on an edge water gets behind and it corrodes.
I stripped it all back gave it a good coat to hydrate80 then epoxy coated - all underbody areas I could reach IMG_1659.jpegIMG_1662.jpeg
 
Kongsodoken said:
Problem with the rubberised undercoating when it’s on an edge water gets behind and it corrodes.
I stripped it all back gave it a good coat to hydrate80 then epoxy coated - all underbody areas I could reach
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Your tray that the ABS module sits on is in much better condition than mine, another job for me when I get the engine running.

Are you going to bond the wings back on to the A pillar or just bolt them up? Currently on mine they are just bolted on but I'm considering bonding them again because I'm worried about moisture getting trapped between the two.
 
dlknight said:
Your tray that the ABS module sits on is in much better condition than mine, another job for me when I get the engine running.

Are you going to bond the wings back on to the A pillar or just bolt them up? Currently on mine they are just bolted on but I'm considering bonding them again because I'm worried about moisture getting trapped between the two.
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not sure about those wheels I think I’ll stay with me Fuch’s - but I do like the rear spoiler

that ABS bracket was quite rusted but I painted it 4 years ago when I refurbished the ABS pump

wings will be bonded back on - it only took a few minutes to get them off once the bolts were out.
 
It’s back on wheels -early offset but not the ones I will be using
all the welding and rust repairs done
getting each panel into epoxyIMG_1835.png
 
So thought long and hard how to do the sunroof delete
the correct way is to replace the roof skin but I didn’t feel confident in removing one from a donor car and welding it back on without distortion.
carbon fibre - maybe but expensive and some skill needed
the fibreglass plug seemed the best option but didn’t really want fibreglass on the roof as that can get very hot and with Expansion may be visible.
cutting a panel from a donor and swaging the edge was a possibility but would require removing all the sunroof support and cutting the flange from the roof skin but then needs tig and skilled welder to get in without distortion.

so I did it my way first brought a 924 roof from eBay £150 there seems to be a few about cut the bit I needed 10mm oversize

IMG_1867.jpeg
 
Templated the roof and cut some jigs 500mm long that matched the roof shape i used these to clamp the panel so it wouldn’t distort.

with the panel clamped I was able to tap down the edge creating a steel version of the fibreglass plug
IMG_1866.jpeg
 
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The edge flange gave stability to the panel and gives me something solid to weld to so hopefully no distortion IMG_1872.jpeg
 
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Happy with the results I have a 2-3mm gap all the way around the panel so I’m going to weld 3mm rod around the delete panel I can then grind this so it’s a perfect fit giving me plenty to weld too and I don’t need to add much filler

keeping the sunroof roof structure keeps everything in place and makes the roof liner simple
IMG_1868.jpeg
 
The original roof skins are spot welded on, fairly simple using a spot weld drill bit to remove the skin, and then weld in the drill holes. If I was filling the hole in the roof with metal I'd tack it in place, and then gas braze the rest.
 
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