S2 Restoration Options.

[Twenny Benson]

DJH PM sent

[djh]

I have another quattro shell.....

[Twenny Benson]

Thanks for the kind words chaps, it hasn't helped my recent dilemma which I've been debating with myself for some time now.

I have been pondering the future of my S2 and the work required to make it solid again, the extent of the rot is quite scary if im honest and its probably too far gone. I'm only kidding myself if I think its going to be alright, at the end of the day the structural integrity of the shell is what will keep me alive and on two feet if it all goes **** up and I'm not 100% convinced it's up to it, well not convinced enough to wager my life on it anyway. I know over time once its driving the power levels will just continue to climb and hence the danger aspect will increase exponentially.

The other side of it is the amount of money required to make the car presentable, it won't be cheap to get it back together and driving again and I have to ask myself if its worth the money for something that will clearly be compromised? I know I swore to see it through but maybe I was a little too enthusiastic and naive. When I read some of the comments at the beginning of the thread and the advice some of the more sensible members of the forum have imparted, they clearly had a better idea than I did. I have to admitt I can be talked into doing just about anything, ask DJH how hard it was convincing me to cut a coupe in half and ram it in the back of a van! Must of took at least 3 minutes!

So I'am on the verge of cutting my losses and parting out what I can to recuperate some of what I've spent. I already own a stupidly fast quattro and another one is the last thing I need if im honest, I commute 60 miles a day and the fuel cost is absolutely killing me. Dare I say it, I desperately need something sensible

I would appreciate some input from other like minded types but I think I've already made my mind up!

[j_jza80]

Top work nice to see it start coming together.

I'm most impressed your cat is 22 though, they normally live for around 15 years!

[aNdreee]

Hello.

Great body work there!, good to see this s2 gets straighten up !

Good luck with the rest

[poor-boy]

Wow.. Brilliant work, Truly brilliant

[Error404]

[Twenny Benson]

Don't even go there!

[djh]

It is rather scary to think the pro's obviously classed this as repaired! I've know doubt that time & the ingress of water have played there part but that was also down to there shoddy efforts. I'm just glad that DJH donated the CQ shell otherwise I have no doubt I would have scrapped it, so big thanks once again dude.

No problem... I have another

[Twenny Benson]

LOL of all the projects I've ever been involved with, business & pleasure they've all suffered spec creep! Nothing ever stays on plan. But I do know what you mean. The problem is that this car needs to be put back together on a shoe string really.

The other side is in much better order yes, luckily there are only a few small patches to attend to and it will be sweet, the entire boot floor pan needs to come out though, its completely ******ed. Im not sure if the worm has crept along under the sealer and eaten it away or if this is more crash damage repairs!

[Error404]

/\ Cool - I always say have a plan and stick to it

Once you get liberal with the cavity wax and seam sealer, should be fine.
I'm assuming the other side if the car is ok? Just the driver side that's been snaffled by the tin worm?

[Twenny Benson]

It is rather scary to think the pro's obviously classed this as repaired! I've know doubt that time & the ingress of water have played there part but that was also down to there shoddy efforts. I'm just glad that DJH donated the CQ shell otherwise I have no doubt I would have scrapped it, so big thanks once again dude.

As far getting the shell dipped, E coated & epoxy primed, not sure. It's a hell of alot of money to throw at the car and money I would never see again. I agree its the right way to restore something but the costs are hard to swallow. This car will need some suspension and brake mods before its trackable and before you know it your edging towards a big budget build, something I've always planned to avoid and besides if it ends up being too nice I won't thrash the life out it on a track which is one of the primary reasons for doing all this. I guess I will cross that bridge when it comes to it.

[Error404]

well done dude, you're making good progress. Each bit of rot you cout of and replace is a step closer to getting it all back together, properly this time
Shocking to see the quality of work that some (most?) body shops will turn out - this had to h\ave been an insurance claim job when it was originally "repaired" which is even more worrying, you would expect it for a cheap cash job :corey:

What is you plan once you've sorted the rot out dude? Will the shell be dipped and coated?

[Twenny Benson]

Quick Update

Progress has been slow, I have just about shook off this winter virus thing knocking about, I'm about a stone lighter now and just about back to full strength, one bonus is I've not had a cigarette in ages and have decided to not bother with them anymore! So bit more money to splash out on the rot box, so no more twenny Bensons for me.

Anyway, progress.......

After finding the bent as fook A pillar, I've removed all the pieces from the donor. Its a shame I plasma'd me way through it really, nevermind.



I thought it was a good idea to put as much back into the floor pan as possible so the whole thing isn't twisted. So I chopped my floor pan piece in half and fitted up one section.



I left a little window in the floor so I can replace the A pillar metal work when the time comes



I also tacked in the floor cross member to try and keep it in shape





I will remove the cross member again when the A pillar is sorted and weld in the other floor pan piece and dress it all back in one go, I have to admitt dressing welds is one thing I hate doing for some reason, especially when the metal is only 0.8mm thick.

Right now before I take the A pillar apart I thought it would be a good idea to sort the B pillar out, I had mentioned previously the B pillar is floating, surprised no one picked up on that! So chopped part of the sill out





Cleaned it all up





I think the flanges need some attention before I can close this section up, you can see the cowboys had a go at fixing the flanges and this is what I meant by a floating B pillar!



Smooth ****ing idiots had used buckets full of filler in attempt to hold it all together :corey:

So the plan is to cut the lower section of the B pillar off and replace it with another piece from the donor as well as some of the flange. I'm still undecided how to preceed with the A pillar repairs as you have to remove some of the inner wing to access the spot welds, very destructive indeed and alignment is a big concern. We will see I guess. I'm hoping now I'm well again to make some real progress to get the car winter proof, the constant rain is certainly slowing me down.

And thats it, slowly slowly catchee monkey

[Twenny Benson]

I think looking at what you've achieved so far, that may be a bit of an understatement

Well I've only really taken it apart thus far, bar one piece of metal lets see what it looks like when it starts to go back together

This is really interesting to see what is under the skin.

Keep up the good work!

Cheers Pal

If i'm honest I find it a little scary how basic it all is, it comes apart quite swiftly once you've found all the spot welds, the brazing is a bit of pig to deal with but I think I've found a work around~ish.

huge respect for your work !

that takes some courage, impressive, keep on man !

Thank you for the kind words, I must admit it is a little nerve wrecking taking a cutting disc to the floor of your car especially if you've never done it before. I just hope it comes back together OK.

Good work dude

Cheers fella