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4wheeledstool

Cavalier mk2 - another blue giffermobile.

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The straight part of the inner rear valance bottom now exists again. There's a world of pain waiting for me in the curved ends where they meet the inner lower rear quarters, but I'll wait until it's on the spit before tackling those. After a quick blast of zinc primer to stop it rusting before it gets painted, it looks like this...

 

post-18211-0-47430000-1554746579_thumb.jpg

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Got a bit of unexpected time on this again today - attention now turned to the nearside rear arch. I began by cutting the arch repair panel in two, then extended the front section so it can be overlapped by the rear section factory style.

 

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Next up, the car lost a bit more rusty metal. (This is by far the best side as it still has a couple of sections of inner arch still intact!)

 

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This enabled the front part of the outer arch to be trimmed to fit nicely with the rear door. (The rear section is just plonked on in this pic.)

 

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The rear section has been partially fettled in this shot - sadly today's time ran out. :(

 

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Hopefully more soon!

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A bit more excavation this evening - the dark coloured part of the rearward wheel tub had a piece of steel rivetted over it to make the lower part of the wheel tub "good"

 

post-18211-0-46090500-1555010984_thumb.jpg

 

Once the bottom of the lower rear quarter outer was cut off, I cut off the poxy left side of the inner rear valance.

 

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A good poke of some suspicious looking metal then turned into a hole through which I could see the contents of the boot.

 

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There was a slightly "blown" section of the inner wheel tub just forward of the spring plate - I knew what to expect, and duly hit it with the wire wheel.

 

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After cleaning up the metal, but before digging out the seam sealer from the other side.

 

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A piece of metal was then shaped to fit into the gap, and both the piece and the hole got some zinc rich primer before the piece was welded in.

 

post-18211-0-90000500-1555011797_thumb.jpg

 

Most probably be recreating the inner arch/valance/quarter bottoms next. :)

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Had another pop at this today - recreating the front of the wheel tub.

A small repair to the bottom of the inboard section, followed by cutting out a rusty part of the outboard section.

 

post-18211-0-75415300-1555172111_thumb.jpg

 

New piece tacked in.

 

 

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Welded in and partly cleaned back. (ran out of time :( )

 

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It may be a while until I get another crack at it, but hopefully more soon.

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Many thanks for the kind words people :)

 

Very little time has been available this week, but I have managed to get a bit done - first up, a piece was fashioned into roughly the shape required to complete the exhaust cutout end of the inner rear valance.

 

post-18211-0-15771200-1555531229_thumb.jpg

 

This was then stuck in position (will be cleaned up better when my back is not so sore!

 

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The bottom of the inner rear quarter is now sporting some shiny new metal where once there was crusty flakes. This bit was a little tricky to get into the right shape, but I'm pretty sure it's right now. (I'll find out soon enough when the lip of the inner wheel arch is completed.

 

post-18211-0-31372600-1555531722_thumb.jpg

 

If I can keep away from the pub this weekend, I should get a decent amount time on it. :)

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Hey Mr Stool, I'm sorry that my first ever post on this excellent thread is purely to ask a question but by any chance, do you know where the fuel pump relay is, on injection mk2 Cavaliers?!

 

I'm in a right pickle with my blue Mk2 Cavalier injection (1983 SRi) and I think the issue I'm having is ignition/relay related, as the pump isn't engaging on start up  - but also I'm getting only a click on the solenoid (newly replaced starter/solenoid), giving symptoms of a duff battery, despite it being the battery off my working car, which starts fine.

 

Anyway, apologies for ramble but hope you may be able to help! I've also seen your thread over on mk2cav.com but figured this is a slightly busier forum to post such a question on.

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Great work on this so far, your welding is superb!

  

 

Many thanks Mr Thecapriman! I've not been welding for very long - I'm hoping that I'll get properly good at it in time.

 

Hey Mr Stool, I'm sorry that my first ever post on this excellent thread is purely to ask a question but by any chance, do you know where the fuel pump relay is, on injection mk2 Cavaliers?!

 

I'm in a right pickle with my blue Mk2 Cavalier injection (1983 SRi) and I think the issue I'm having is ignition/relay related, as the pump isn't engaging on start up  - but also I'm getting only a click on the solenoid (newly replaced starter/solenoid), giving symptoms of a duff battery, despite it being the battery off my working car, which starts fine.

 

Anyway, apologies for ramble but hope you may be able to help! I've also seen your thread over on mk2cav.com but figured this is a slightly busier forum to post such a question on.

I have some wiring diagrams in the shed - I'll dig them out over the weekend chief. :)

 

This morning was all about fixing the hole that allowed the contents of the boot to be viewed through the wheel arch.

Chopping out the poxy bits

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Piece let in to boot floor then zinc primed

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Another piece then made, and let in to the wheel tub to complete the repair.

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Once I've replaced the seam sealer that was dug out, it should be barely noticeable.

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Got a bit carried away today, so theres bugger all pictures. A piece was made to go at the back of the outer wheel tub.

 

post-18211-0-75309300-1555779355_thumb.jpg

 

Then using the outer lip of a spare repair panel and more sheet steel, the inner arch lip was recreated to fit nicely with my outer repair panel halves. It took a lot of time to make it all fit (outer panels off and on many times) but finally I'm at the stage where the outer panels can be attached permanently. :)

 

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post-18211-0-68292500-1555779710_thumb.jpg

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Got a whole day on this today - kicked off with fitting the front half of the arch.

 

post-18211-0-77688800-1555957007_thumb.jpg

 

Ground back and zinc primed to stop it rusting before it gets painted. (Some time next year hopefully!)

 

post-18211-0-06825200-1555957124_thumb.jpg

 

I got carried away again, and forgot to take pictures of the rear part going on, but here it is cleaned back and zinc primed.

 

post-18211-0-49641800-1555957263_thumb.jpg

 

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I made a bit of a balls of this and ended up with some warp related high spots. Hopefully I'll be able to get at the back of it with a dolly and level it out at some point before paint preparation.

 

Finished the day by putting the rear quarter bottom on.

 

post-18211-0-16668800-1555957697_thumb.jpg

 

Once I've plug welded the inner and outer arch lips together, and done the same with the inner and outer quarter bottom, this corners completed metalwise. :)

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For someone who says he hasn't been welding for long that looks pretty damn good to me! Nice to see a Cav getting this level of attention, they all seem to have vanished overnight a few years ago round here. We had three in the family in the eighties but the one I remember the clearest was my grandfather's gold 4 door GLS, B898MDX. Sold in 1989 and never seen again, I used to see an identical example knocking round Earlsdon when I lived in Coventry about fifteen years ago but not another since then.

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Plug welds to the arch and lower quarter bottom now done, I removed the rear door so that I could finish and tidy up the welding to the sill.

 

post-18211-0-67897000-1556286368_thumb.jpg

 

I need some time to contemplate how I'm going to tackle the clusterfuck of corrosion that is the offside rear arch.

 

post-18211-0-32390800-1556286489_thumb.jpg

 

post-18211-0-78490300-1556286517_thumb.jpg

 

Ummmm.

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Hey Mr Stool, I'm sorry that my first ever post on this excellent thread is purely to ask a question but by any chance, do you know where the fuel pump relay is, on injection mk2 Cavaliers?!

 

I'm in a right pickle with my blue Mk2 Cavalier injection (1983 SRi) and I think the issue I'm having is ignition/relay related, as the pump isn't engaging on start up  - but also I'm getting only a click on the solenoid (newly replaced starter/solenoid), giving symptoms of a duff battery, despite it being the battery off my working car, which starts fine.

 

Anyway, apologies for ramble but hope you may be able to help! I've also seen your thread over on mk2cav.com but figured this is a slightly busier forum to post such a question on.

Apologies - I've just remembered! I believe the fuel pump relay is positioned on the nearside front suspension turret. :)

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Nice work, 4wheeledstool! Can't wait to see the finished article. :)

 

I had a fancy for the mark 2 Cavalier back in 1997. It's on my 'cars I regret not owning when there were still plenty around' list

 

I was 19/20 at the time and I had the perception that 'all 1.6+ litre engined cars will be expensive to insure' as a student working part time. The 'easier to insure' 1.3 Cavaliers were thin on the ground iirc. My parents had a Carlton 2.2i CD at the time so a Cav would have been nice addition to the family fleet.

 

The Carlton made was for an Astra III California later in that year. It had retro fitted power steering. :mrgreen: I actually got an insurance quote on the Carlton: £820!

 

I'm not jealous of any BMW or Mercedes owners on Autoshite but I am jealous of the Cavalier and Carlton owners. ;) I can't explain.

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Lovely repair work going on here. Fortunate that you could get the panels ready made, I can't begin to imagine how much a ballache making that rear outer arch from scratch would have been.

Many thanks! Indeed - the Klokkerholm outer arches don't fit particularly well as they come, but fettling these has saved a ridiculous amount of time that would have been required to attempt to make them myself. (and probably make a mess of it!)

 

I'd probably exchange a testicle for an offside rear wheel tub + quarter panel at the moment, but I imagine it won't look so grim once I get stuck into it. :)

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Nearside sill now finished off.

 

post-18211-0-80778300-1556390160_thumb.jpg

 

I decided to have a look at the offside rear wheel tub - this was how it looked to begin with.

 

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Once it had seen some wire wheel action, and a couple of bits of metal that were held in with filler had been ousted, I could see the extent of the job in hand.

 

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It's not very clear just how much metal is missing in the above pic - I'll try and get a better one at some point! The inboard side of the tub is pretty good - just one small repair is required right in the middle of the bottom edge.

 

post-18211-0-80023500-1556390720_thumb.jpg

 

Due to a complete lack of arch lip reference points on this side, I made a start by getting the front part of the outer arch trimmed and positioned so I have something to work to when rebuilding the inner arch/tub.

 

post-18211-0-03284600-1556390934_thumb.jpg

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A top bloke of the retro rides forum gave me a load of arch repair panels out of his old shop stock. He also supplied me with a pair of rear drums, several sets of rear brake shoes, two sets of front pads, two rear wheel bearings, and a pile of mirror glasses.

IMG_20190429_171210.thumb.jpg.b5576fda5e26ba7576a96f99ef7704fa.jpg

Should save me a few quid when the time to rebuild comes. ;)

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