DDK - Die Deutschen Klassiker

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Must have felt like a satisfying couple of days' work Mark ... well done


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Order yourself some epoxy mastic if you don't have it and give everything a good coating before putting the rear wing section back on.

Gents, I need some cross-Atlantic translation, please: epoxy mastic...two-part epoxy primer, but brushed on? For better or worse, we don't use the word mastic here, but from my days as a lad in Brissle, I associate it with something more gummy or at least thicker and more viscous. Any clarifications appreciated. Thanks, John

You’re right Andy - it was great

Good call Jon.


No problem John

This is the stuff

https://www.rust.co.uk/product/cat/em-1 ... is-paint-7

sladey wrote:Made up a repair patch



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Nice work fella, I hope you managed to get the curtains back up before the Mrs got home though?

Glad to see the panel turned up in good time and that it’s been of use to you, great looking project you’ve got there.

No problem jevvy - she’ll never notice they’ve gone

Thanks Sam - the part is just what I needed. Seemed a shame to be cutting off the engine mount to get at the bit I needed but needs must

OK I”ll do a bit of progress report before starting again today

I’m starting with the bit in the photo above. I cut down my repair piece to the point where I could clamp it on top



With it clamped on top I scribed all the edges in the original panel underneath.

I then cut near to them with a grinder and cutting wheel and used a sander to take it carefully to the edge


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This produced this



Took a bit of jigging about - the flange on the left was bent a bit so when you clamped it down it threw the rest out. I straightened it out and it sat OK


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Then sprayed the back of the repair piece in weld through primer



On the body I masked up and sprayed the back of where the seam weld would be in weld-through primer
Then I worked out where the plug welds would be, sanded them back to bare metal and spot sprayed them in weld-through primer

Then I sanded back the inside of the cavity and treated it with Fe123 rust converter. This converts any rusty steel to a black hard surface. I forgot to take a photo at that stage. Once that had dried I sanded it down roughly by hand

Then I epoxied the back of the repair piece and all the inside of the cavity - staying clear of the bits with weld-through primer on them


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Then it’s welding time. This is part way through the process




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and this is with it mostly smoothed down



Back onto it today


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Good stuff Mark,
I've taken to removing tiny patch of 'weld through' primer from behind the the plug weld. Splatter central otherwise!

More progress today

Marking out




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Then cutting out - brave pills required



After cutting I was relieved to see how thick the steel was - even though it was pitted


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