Mr Hyde Estate, aka The Milf

[dr_jekyll]

Cheers, nice update. It's looking good. You've taken a car that was headed for the scrapheap this far so you might as well sort the rear quarter panel properly. As you say, it looks like it's got in there good but from what I've seen of this and your previous projects you're more than up to it! Looking forward to hearing more in the future.

Cheers dude [emoji869][emoji869][emoji869][emoji869]

So small, big update on todays main event. Welding ended up being a bigger task than myself and my mate had anticipated.

So once the interior panel was drilled out on the spot welds, cut and removed it was pretty clear the rot had spread fully into the seatbelt mount and the main C pillar member.

Pretty much a standard case off cut the rot out, fabricate the part and weld it back in.

The captive thread on the seatbelt mounting plate itself was rottern as hell. After cutting the rot off and welding a new section on we needed a new seatbolt thread, luckily had one kicking around in the pile of 205 gti cuts I've aquired over time [emoji28] unfortunately its not captive so will need greasing to hell and back to prevent grime from siezing it


Once the internal C pillar was re- constructed we began breaking down the complex shape of the internal skin into manageable sections saving what we could. This will leave the panel in the closest possible shape to factory. Ideally this wanted re-making as a single piece or a good cut sourced but tbh neither of us are panel beaters and every estate ive locally found has had a shit repair job already!
Either way, even with the patch work quilt finish i dare say there will be very little loss in strength with the penetration achieved on my mates welds [emoji28] unfortunately we ran out of hours tonight but this is where we got upto.
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So tommorow theres still some to be done. A single patch to go back in here. Then a little bit in the boot floor skin near the nsr pocket and and one small square in the osf floor pan. That should cover all the welding in the car ready for the mot then!

All welds are being dressed in zinc primer after, with a brush able seam sealer and then stone chipped in white. Ideally id love to epoxy prime it but with a night shift looming for me were stuck on a time constraint