DDK - Die Deutschen Klassiker

A little stroke of luck - I discovered that carb cleaner dissolved the plastic horn. One of the horns had a little crack in it, and I was able to dissolve the edges of the crack with carb cleaner, clamp it back together and achieve quite a satisfactory solvent weld repair.

I painted some of the surfaces with direct to rust paint:



All the removeable parts went into the ultrasonic cleaner with some other bits and bobs - to be painted/reassembled once dry. I'll replace some of the nuts & bolts with new where I can.

The MOT tester said this riveted on plate in the floor was "a bit naughty".

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There's a tiny touch of rust at the base of the inner sill near where it meets the floor. I thought I'd tackle a quick job today by cutting it out, weld in a repair and only tack it to the floor pending the full floor repair.

I don't want a prolonged period unable to drive the car until early next year so I'm trying to keep jobs bite-sized.



EDIT: THIS PHOTO IS ACTUALLY THE CENTRE TUNNEL SIDE

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The gap at the base of this door is no good, even before I start. The base of the door has definitely been refinished. I think it likely this side has had a new outer sill too.



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I cut back around an inch strip along the bottom of the inner sill to confirm the metal's full thickness. There's no corrosion at all at this height and I can see the galvanising on the inside.

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Unfortunately one thing led to another...

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I have separate front and rear floor panels. I was planning on using them for isolated patches.

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That escalated

You’ll need to make a new edge return flange for the tunnel by the look of it. Are the seat mounts ok?

Gary71 wrote:That escalated

You’ll need to make a new edge return flange for the tunnel by the look of it. Are the seat mounts ok?

A small section of the tunnel flange under the seat mount needs reconstructing. The bottom of the offside outer seat mount has about 4 inch strip that need repairing, but only the very bottom. It's little enough that I'll be able to put the floor in for a shape and then work back to that.

There's also a bit around the front wheel arch where I have nothing to weld the floor to.

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There wasn't any rust in the floor to intermediate sill seam. I was tempted to weld straight on to it, but Barry convinced me it was better to drill out the welds and have a double seam rather than triple.
It sucked up a lot of time splitting this seam, but deep down I know he's right.



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The very rear of the panel under the seat mount is the only bit that was a poor fit. There's a brace coming down from the seat which the floor welds to. The floor will need drilling through in order to pin it on. Here I'm bending the panel to clear it.

This is as far as I got... rain tomorrow apparently


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If it helps this is the repair I did for the bottom of my seat mounts. I took them out by drilling out the spotwelds from above then fabricating a new bottom before plug welding them back in .

The flanges are relatively straightforward, if you have a shrinker/stretcher to get the curves.

Gary71 wrote:If it helps this is the repair I did for the bottom of my seat mounts. I took them out by drilling out the spotwelds from above then fabricating a new bottom before plug welding them back in .

The flanges are relatively straightforward, if you have a shrinker/stretcher to get the curves.

Thanks. This shows how much rust I had to cut out of the seat mount, just at the front. I can reconstruct it in situ. There's an internal foot that comes down to the floor, which WAS fine until I chopped a chunk off with the floor, so I'll patch that before the new floor goes in.


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This is the spot where I was a touch overzealous with the chisel. I'll remake this foot now because it won't be accessible once the floor's in.

I have a much better situationtoday with the side of the car on Ramps rather than the rear, so I have much better visibility.



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There's the foot for the seat mount.

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