DDK - Die Deutschen Klassiker

Nice patch, sounds like you are 100% full of confidence now with anything you may find.

My screen corner on the OS was like you NS picture, a real pain as I had no repair panel.
Top part is easy, I found getting the other lower panel the worst bit to shape right and in the correct position to weld the top to.
I added a drain tube.

I’ve (almost!) accepted it’s not going to hit my old CLM 2020 deadline, so I’m trying to compromise less now.

Which means going back over areas again.

There’s nothing on this inner wing that wouldn’t last another 10 years, particularly with a thick coat of paint, but it really could do with fresh steel and now is the time.

I wouldn’t say full of confidence, it still frustrates me, but I find I can get to the final answer in less steps now!

It will probably go to Barry at the end of the year and then have to come back via my garage again to finish some of this off before even thinking about paint.

.. but you're still coming to CLM though .. just maybe in something more modern ?

Oh yes, still coming. Probably in a new Audi which won’t be the same!

try get a VW california

Luckily despite the little hole in the screen rail nothing seems to have leaked through as the metal underneath was sound and still had paint and wax on it. Made a little bent and stretched section and then made the rest out of weld



Then made a big hole and peeled back a crusty layer or two at the top of inner wing:



Next step is to finalise cutting in that patch then make the fold over the inner wing.
Then I’ll cut and shape the screen rail repair before welding.

You are making some great repair panels there Gary. I've never tried stretching or shrinking, am very impressed with what you are achieving

Cheers, the stretching/shrinking is easy enough as I’ve borrowed a machine!

Got the main panel cut and welded in today and started on the screen rail, including the little bracket that supports the rubber strap around the expansion tank.



I’ll get that welded in tomorrow as it’s all ready to go.

Lovely work Gary....really neat....

Nice work Gary

Thanks guys, finished this corner today. Pretty happy with it overall.

Is there no surface rust on your repairs Gary?
Everything seems bright!
Nice progress.

Nope. Pretty much stays like that indefinitely, although I did only do this a few hours ago
There’s bits under the parcel shelf I did months ago that are still bright.

Randomly the odd small patch does get a surface flash on it, I guess from me sneezing on it or something

Cleaned out the smugglers box today, what a grim job. Multiple layers of paint, underseal and general filth.

Three hours of various wire brushes it went from a black hole to a shiny hole!

And then almost immediately back to a black hole again


At least I know it’s solid and well protected now. I’ll get the paint shop to blow some green over it, but the finish was never good anyway and durability is the priority.

I met with a local paint shop today and had a good talk through the job. Just awaiting a quote now...

More dirty work today. Making sure I’ve found everything inside and out before painting. I’m going to brush the areas where stonechip is applied and leave the rest until I can summon the courage to work out how to spray 2k epoxy.

Anything’s near where Barry needs to work will be left clear by a good 100mm.

Still a long way to go before painting it, but you can see the light at the end of the tunnel!