My 3B project (ongoing)

[Dobby84]

Keep up the good work. What do you call the tool used for copying the profile of the sill?

https://www.amazon.co.uk/gp/product/B09298HVFW/ref=ppx_yo_dt_b_asin_title_o05_s00?ie=UTF8&psc=1

[Dobby84]

Bit of an update guys.

Finished welding the sill but need to do a bit more work on it. Don't have a photo of it finished but will get one soon.

Started to look at the rear quarter/sill/wheel arch and after cleaning it up and removing lots of filler it is even worse than I expected. and had previously bee repaired.
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Started cutting back to good metal and made some patches. Got the first welded in. Its okay but not perfect. should be able to finish it off with some filler. etc.

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Started making up the next patch for the inner arch and sill so hopefully will be able to make some more progress next weekend.....

[Dobby84]

Been a while since I updated this thread due to life getting in the way.

Finished all the patching and welding on the rear arch and sill.

Filler applied and sanded back ready for the second application of filler and more sanding. Also sorted the rear corner out and applied some filler ready for sanding back.

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[Tom_]

Nice work Dobby, hats off that you don't scrap that car and you repairing it. I like your attitude, keep going, the car looks already much better.

[Dobby84]

Nice work Dobby, hats off that you don't scrap that car and you repairing it. I like your attitude, keep going, the car looks already much better.

Thanks for that. It's been hard getting motivated recently but that's mainly down to having to learn new techniques and being a fairly complicated repair. Think I've done a okay job though.

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[B5NUT]

Motivation can be difficult when you get to the tricky / boring jobs. I'm at the point where I'm rubbing down my A4 ready for paint and I'm struggling with the motivation. So thankful my S2 did not have any rust like that, well done on the work so far.

[Dobby84]

Right I have just realized that its been over 1 year since I have updated my thread so I though I would show you what I have been up too.
Progress has been slow but hey its moving at least.

Probably be a few posts with all the photos I have but here goes......

Striped back the OS to bare metal and primed with Epoxy primer for now.
Red dust everywhere so half my time was spent cleaning up.

[Dobby84]

Next it was onto replacing the poor bodywork.
I managed to source a donor car (2ltr 16v) to butcher for the repair panels and roof that I needed.

First task was to swap the roof skins.
First I had to strip both cars down, Then it was out with the drill.....this was a big undertaking due to the amount of spot welds that needed drilling out and welding back. But after a few weeks I managed to complete this and fairly happy with the result.

I then decided to sort out the rear NS light area when there had been previous crash damage.
Cut the section I needed out of the donor, and the same section from my S2.
Tacked in, welded up and with some filler and primer I think it turned out okay.

[Dobby84]

Now onto the lower rear quarter panels. I know I have previously repaired one side but decided to replace them so I could install the lower door trims again.
Out came the grinder again and cut out the required sections from the donor and at the S2.
Welded in, filler and primer.

Bare in mind I am not a welder or body work specialist by trade and just learning as I go so the result is acceptable in my opinion.
I will be going over the whole body at a later date so will sort out and fine tune before I attempt to paint it.

Sun roof installed

Doors boot and bumper on and body work done for now.

Now onto the engine and getting this thing running....

Do you think the MOT tester would pass it looking like it does??? LOL

[Nuvo]

That's quite some undertaking, all the more impressive considering you're not a pro. Well done.

[Antsa]

Thats a massive amount of work. Cutting and welding body panels plus painting them so that the repair is not visible in any way when finished, takes a lot of time. Nice work

I've recently cut and welded both rear quarters for my Avant. When everything is done and in fresh paint, it will be worth it.

[Dobby84]

Thats a massive amount of work. Cutting and welding body panels plus painting them so that the repair is not visible in any way when finished, takes a lot of time. Nice work

I've recently cut and welded both rear quarters for my Avant. When everything is done and in fresh paint, it will be worth it.

Yeah i would say it's been a labor of love but doesn't feel that way at the moment but it will be worth it in the end. Plus I'm learning a lot.

Next step is engine out and clean up the bay ready for paint

[Rikki Kitto]

Amazing attitude, Bro I caved in and sold mine and it was no where near this bad so I have total respect for you brother these cars certainly need a loving home and owner, keep it up it'll be worth the effort for all the looks you get when driving it did it live near the seaside by any chance

[K Simmonds]

You've done an excellent job of cutting/splicing in the repair sections and reskinning a roof is no joke at all, that's a very time consuming fiddle **** job!

Well done for sticking with it and saving the car!

I expect you're getting pretty handy with a MIG by now!

[Dobby84]

Thanks for the words of encouragement guys, definitely helps spur me on.

Roof skin was a big job but surprisingly straight forward, although very long and tedious. I was convinced that I had not lined it up and the rear windows would not fit after but thankfully they do.

My welding has certainly improved although I would say its more functional than pretty but should do the job and you wont see it after I have finished......