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Hopefully I can clear some space inside the garage at least around the area where welding would happen. I have a pile of scrap body panels stored inside that have to go. I also have water hose inside so I can keep it right next to me if I decide to weld inside.
If you were local you could borrow my dolly. Custom made for an S2 Avant.
I would weld inside. Just clear any combustible material and have a hose ready just in case.
It's amazing how much they can pack stuff on a car. The subframe will propably be installed back for a little while to make it easier to push the car around. My plan is to do the welding work outside if weather allows so no sparks are flying around the garage.
That's going to keep you busy.
I had the same issue with storage so invested in some second hand industrial racking shelves.
When you take a car apart, it's surprising just how much space everything takes.
Today I had a somewhat productive day. Driver side rear quarter panel out. Same rust issues as on the other side. The bottom piece of the boot is little annoying to remove because the spot welds are in tight spots. I wonder how they welded this in the factory?
Thanks Dave. I used a small 10x330mm belt sander and a drill in places where I could drill through the welds. I have already used six or seven p40 sanding belts and the left side is not even completely out yet. The belts wear out pretty fast.
After both quarter panels are off, I have to drop the rear axle plus fuel tank to safely remove the left and right trunk bottom pieces and then I can copefully start welding new parts back in
Impressive work. That's no small feat cutting that out and it looks like you have done a neat job. I cut out a rear quarter for a friend who wanted one. Took ages and a dozen thin cutting discs. Strangely, he never collected it and it's still sitting here
The sunroof drains right above the vent hole. All the water that exits the drain pipe drips onto the vent and despite it having a seal, water finds it's way inside and corrodes the bottom of the trunk. I have ordered new drain pipes and if they are long enough I will extend them past the vent hole.
The right side quarter came off. It took several hours since it's first time for me ever doing this.
The outer metal mudguard has a rust hole in it. My original plan was to replace the whole mudguard, but it would get too invasive for me to do. What I'm going to do instead is cut the rusted parts out and cut a replacement piece from the new mudguard.
Today I had somewhat productive day. First of all I took the pedal box out and when turning it over in my hands I managed to break the gas pedal Luckily tradition has the pedal in stock.
Then it was time to remove the headlining. I used a couple of boxes and an old towel for support. Wifes hairdryer came in handy when softerning the glue.
This cover sorrounding the sunroof opening gave me little head scratching how to get it out, but a little search on the forum and a look in the family album confirmed that it held in by clips and just needed a little persuasion to make it loose.
Before leaving the garage I thought of breaking loose the crank bolt. I tried a little dangerous looking system to hold the locking tool in place. It did not work. I just realised that I have a tool for AAN engines and the the correct tool for ABY should hold against the snub mount. I have used this tool before but I can't remember how I made it work. I think I should be able modify this tool to suit.
Next I'll try to modify the locking tool and loose the bolt before taking the engine out. After that I will have to figure out where to get dry ice in here and also prepare to take all the glued windows out. I also need to start thinking how to remove and replace the rear quarter panels.
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Luckily tradition has the pedal in stock.
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