DDK - Die Deutschen Klassiker

Nice work Gary

So now we are getting serious...

With one 20 second move I removed my previous repair under the torsion bar that took me two weeks to make a few years back.



The big repair panel:



And the bit I’m going to use:



Cut a bit more of the inner sill out and replaced the flange along the edge.



And another dry build so I can see where I’m heading!


The plan is to complete the area around the torsion bar and finish the rearmost section of the seal flange then repeat the whole process on the other side and then do the back half of the floor.

Just one paragraph.
How long will that take

Not too long.
You are getting quicker at these things!
Intricate area to do and I'm green with envy.
My 'area' in the same locations still have the fixes (crude) done back in '89, both sides; solid, good for MoT for 30 years but not pretty.
Wise to leave the torsion tube and bush fixings as is I think.
Nice job!

I was going to replace the ends of the torsion tubes and bought the machined sections to do so. It doesn’t need it and it’s massively intrusive so I’ll sell them on.

One of today’s job was cutting the remainder of the quarter off and replacing the window flange. Looks simple but it’s position is key so lots of scribing and measuring to match up the new one. It’s too wide obviously, but that can be trimmed once the new quarter is on.



I’ve decided to leave the welding of the torsion bar area until I have a floor in place so time to move on to the other side. Cut the quarter off (much quicker this time!) and set to with heat gun and angle grinder. Hateful job but all clean now.

Kidney bowl is original and in surprisingly good condition, but it’s coming out as the bottom has seen better days from previous jacking point repairs. Hopefully the flange behind it is sound, certainly the upper section past the tank strap is good.

The bit I didn’t mention was the ancient patch over the oil tank mounting. I’ve known it’s been there for ever, but always ignored it!



Luckily a big socket and wheel bearing inner and outer races are within a mm or two.



Cut and ready to weld in.
But time for the pub.

Like the approach for the patch around the oil tank...spot on for practicality...

Nice work again Gary

Cheers Mark, Barry has guided me to use more self tappers and dry build the outside of the car after doing this bit.

So the next job is cleaning out the flanges on this B pillar then cutting into those precious quarter panels...

Now welded in:


Ground off and flange removed ready for a new strip of steel.



Kidney bowl removed to reveal...
Solid steel! Well apart from the two holes I drilled in it by mistake.



Luckily I don’t have to repeat the big repair I did to the inner wing on the other side as this is all in really good condition. Obviously jacking point etc is coming out. Removing the previously plug welded flange of the old quarter whilst minimising damage to the inner took over an hour...

The nice non A surface structural work is on stop for now until I’ve done a full panel fit.

First up the new wing, door and offer up the quarter.



Looks good from a distance, in reality absolutely no where near fitting!

So angle grind your new panel and take the outer B-pillar off, having made an accurate, but cosmetically challenged template for the window first.



Starts to fit a bit better:



Still loads to do, not least the other side before I can commit (self tap!) too much together.

Many hours pass...

A-pillar repair panels now cut in, inner & outer sill aligned, door on and off about 10 times in a day



Time to leave that side alone and get the other side to the same point.

I’ve cut the sill off to reveal a mess, some reconstruction of the seat support flanges will be needed before the floor can go in.



Annoyingly my left elbow seems to be violently protesting at excessive hammering, lifting and angle grinder abuse. So rather than rest it, which would be sensible, I’ll be back on it tomorrow.

Good lad...proper man attitude..f**k wimpy health and safety bollocks...

How I remember those times on my T.
I had Dansk sills and fresh door skins to contend with in the mix which really did not help.
It was all a real bitch and very challenging cramped in a one car garage.

Hard work now, will be fab when done and sealed ready for paint.
You will see those gaps every time you wash it, so best take the time!

I didn't back then and those mistakes haunt me today.

As to aches and pains, well I would do the same as you, get it over and done with ready for the next stage.
Whole job is looking great!

This side needs a bit more work as the A pillar rust goes above the repair panel and into the area around the hinge mount.

I don’t like to criticise previous repairs, as I sometimes have to compromise my own work, and in previous times the value of the car didn’t warrant the effort, but this A pillar lower is a shocker!

What a pain in the arse this area is! What looked like a ‘simple’ surface in cardboard above the repair panel and into the hinge mount was anything but in steel. Got there eventually, but disproportionate to the size of the thing!

The repair panel is too wide so had to be tweaked. Weird as the other side fits!



I had hoped to get the quarter on and dry fit the sill this weekend, but lost a day with this little time hoover!