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Old 12-05-2018, 07:19 AM   #1091
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So, a little progress, but not much....

The chassis panel arrived from Belgium. Pleased as this is for the passenger side and that side has been patched (very neatly and well I might add) in the past. I think I'll end up replacing the whole panel. Alignment issues I was worried about can be overcome by bolting up the subframe and using as a guide.





Onto the windscreen VIN template. The bloke who made it for me sent me it in a file format I could print out. Armed with half a dozen copies, i cut out the print off, stuck it to a sheet of vinyl and got punching. Now initially, I'd ordered a 1mm punch as this is the size of the dots. However, it's slightly tapered and as I was punching through, the punch would go through further and open out the holes too much. Hmmmm. Didn't help I was punching onto a sheet of card.





Ordered another punch, this time 0.5mm and at Cookies suggestion, nicked an old plastic chopping board from the wife and punched onto that. Much better results.



Still a couple of issues to resolve. The template size isn't quite right. Compared with the original, it's not as wide although letter height appears about right. I will remeasure and see if Rich can alter it. The W on the print off is also wrong compared to the W on the screen. Couple of extra dots along the base which should be easily sorted. I'm also going to try printing directly onto the reverse side of the vinyl and punch through from that side. Means the side that will sit against the screen for etching will have the cleaner punch marks.

Oh, and Niall, yes, you were right ...it would be backwards (cider addled brain did not compute correctly last night!!) I'll need to flip the image if doing this.....
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Old 12-05-2018, 07:41 AM   #1092
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Quote:
Originally Posted by Ben_W View Post

Oh, and Niall, yes, you were right ...it would be backwards (cider addled brain did not compute correctly last night!!) I'll need to flip the image if doing this.....
When you said it wouldn't, I just assumed you were going to flip the text.

None taken....Lol





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Old 13-05-2018, 10:56 AM   #1093
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A bit more experimentation with this template making lark.....

Definitely working better if I punch the image in reverse....the side that will then sit against the screen when etching is much much cleaner. Also seems to work better if I use the punch and roll it between my fingers (whilst holding vertically) to kind of mark the vinyl where I will punch later. Takes time, but a better finish...

You can see the difference here...the letters I punched above the few I've done were done the old way and would have been the side that sat against the screen....you can see when the vinyl has been flattened how much shape the dots have lost...



Started the different technique from the number 3....you can see the difference...



This is where I marked it before punching....



I will also draw a grid onto the letters when I print it into the vinyl. Will help me keep things dead straight. Once I've perfected the technique, I'll get the template size adjusted and try again!

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Old 13-05-2018, 09:35 PM   #1094
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So with the forecast for.today being awful, I hadnt got much planned. In the end, I think the forecast rain came early when it arrived late yesterday so today the weather was great so after bumbling around most of the morning, I nipped out to see a mate and borrow some spot weld drill bits. Got home, got busy.

It became apparent fairly quickly that removing this panel was exactly the right thing to do. Drilling spot welds around the section where it wraps around the main chassis leg was interesting....lots of rust coming out. I knew it wasn't great, this had me worried though.













I eventually drilled though enough spot welds (and the floor in a couple of places.....) to enable me to get a cold chisel between panel and chassis leg. The metal was so thin and brittle, it took next to no effort to split it and peel it back. Yuck. Chassis leg appears solid, although I won't know for sure until the panel is fully stripped off but the inside of this panel is rusty too. As said, I'm happy I've taken the decision to strip it off.









The other side of the car is worse. It's already been patched previously to me owning it. It's a tidy job but there is double skinned section very near a subframe mount which looks very rough indeed. It's a double skinned section and I can see the second layer....red circled bit...



Desperately need to find the panel for the other side. Craig is on the case but it's not readily available to him on his list of parts that he can see......there was one listed but wasn't there when called on. The search continues.

Last edited by Ben_W; 13-05-2018 at 09:37 PM.
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Old 31-05-2018, 09:11 PM   #1095
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So having the week off, and it finally stopped raining today. So we went shopping

Once that was out of the way, i decided that the rotten stiffener panel would met with a timely, horrifc death consisting of fire and brimstone (well, a cutting disc on the grinder..... ).....which it did. Its taken a while and its been a pig of a panel to get off, but its off.







Appears only the panel itself was the rusty/rotten bit. Chassis leg has some surafce rust and a very small amount of pitting but other than that, is all good underneath. New panel fits well, which to be honest, i guess you'd expect being a peugeot panel.



Still searching for the other one, weve had no luck finding that so far, which is a bit of a bugger as the other side is perhaps the one more needing of replacement but ill do both as long as we can find it....
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Old 03-06-2018, 06:02 PM   #1096
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Got a bit more done today....

First job was to finish tiding where the old stiffener panel came off. Easy enough to do. Had to get the cutting disc on just to cut off a couple of small bits of old panel but all done easily enough. I then got all the exposed and cleaned up bits sprayed with Electrox.

I then had a look at the brake line clips in the front inner wings. Now, I never removed these for blasting as they were a pig and would come off but discovered they are in a threaded stud and just screw off. Needed the grips to hold and twist them to break them free of the rust but glad I did....underneath, more of the factory stone chip that whilst not looking brilliant, didn't look too bad. Until i peeled it back....again, failure of the coating and rust with a radius of about an inch, out from the base of the stud. 5 mins with the grinder and brush and all sorted....











Then onto the next job. Still have the servo I took off the 6 I broke. One in the Rallye currently isn't great at all cosmetically so decided to clean this one up and will replace the one in the car with this.









Mostly done. Just the joint between the two halves to do but that will probably need blasting to get in there. Undecided if I'll paint or powder coat this....

Then spotted a bit more I wasn't happy with, but only noticed it when the car was.rolled over as in a tight bit of the engine bay. Again, grinder and brush and sprayed with Electrox.





Last job of today was to offer up the new stiffener panel now all the old bits were out of the way. Fits very well indeed, couple of tweaks and the fit is great......







Apart from this bit. Still too much of a gap for my liking. Little more.fettling required.

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Old 03-06-2018, 06:59 PM   #1097
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That's a very productive day right there, bud. Good job you spotted the bits under the threaded stud!!

N

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Old 03-06-2018, 07:54 PM   #1098
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If you're going to powdercoat that servo, I'd recommended dismantling it - I ended up doing it to mine. Panels fitment looks spot on pal!
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Old 03-06-2018, 08:32 PM   #1099
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Thanks bud. Yes, panel fit is pretty good apart from the one section. Having said that, it's an OEM part somperhaps the fit should be pretty good!

Thanks for the tips on the servo. I think I'll probably end up painting it rather than powder coating it
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Old 17-06-2018, 08:16 PM   #1100
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Today, having watched the last half hour of Le Mans (really got into that this year….watched it late into the night last night, loved it!) and having done all the fathers day stuff (including going to see my dad, who wasn't in, and landing sunday dinner cooking duties!!), i got to play a bit with the Rallye.

Started out by doing a test section on the underside where i wet sanded the zinc primer. Like the small section of Epoxy mastic, im not happy with the brush marks in the finish. BHs guide say it can be wet sanded to a point. Im planning on wet sanding and then asking my mate if he can spray the new 1ltr tin i have (again, can be sprayed if thinned correctly). I'd like a really decent finish on the underside too. Not sure if i'll have to wet sand too much of the original coat to the point it wont protect properly so as i've got some more, i'll get it sprayed on. Didn't get any pics of this although i'm sure you've all got an imagination

Next step was to get rid of some more of the blast media that still seems to in there. This inside the inner wing.



A slight opening up of the panel and out it came.

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So with that done, i decided to move onto the heater fan….thanks to Mr Blaster who just seemed to shove the nozzle anywhere, including fan air intake, the fan was full of media. Joy. So i started by popping out the glovebox (pain as the hinges have two plastic pins needing removal, one of which you need to be a contortionist with the hands of a 5 year old to get to. Removed eventually. Popped the rubber cover off the power & earth wires and media is peeing out already. Not good.



Wires removed. You can see around the joint line on the fan unit and on the bracket i removed the evidence of the matrix failure.



What has someone been doing to the wiring? I need to chase this back further and see what is what...



The fan innards…..yuck.








This is what came out of it….



Evidence of the previous (known about) matrix failure



Then, the piece de resistance…. I had a look at the bulkhead and though hmmmm, sound deadening looks a bit odd. Because it is. Someone has been at it with a stanley knife.



Couldn't figure out why, until i pulled the carpet forward. WTF is that i thought? Very quickly dawned on me that someone has drilled the bulkhead. Ill guess to run a power cable to the boot for some stereo gear, i can't think why else, unless its had a battery relocation done at some point in its past (i know it was stripped to be a track car) but havent found anything else to suggest this is the case



The offending bulkhead hole.



So a little more welding to do and more parts on the shopping list. Ill test the fan motor on the bench but might put a new one in for good measure. The housing it sits in has clearly been prised open as the two halves don't go together properly and clips are broken. Pain to change that and i may well yet have the dash out completely. Need to chase back that fan wiring and see whats what and im half tempted to chuck another matrix in it while the dash is out.
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