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Saab 96L - An Occasional Series.


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Moving on to the front left wheel arch.

IMG_20210101_112344.thumb.jpg.f762ffbe0f23d3f0609c474f1b54ede3.jpg

This strange looking patch is at the junction of the inner wing and the front valance.

IMG_20210101_122208.thumb.jpg.fa3a9c325d3c3eb877d3c9b1ac321687.jpg

What lies beneath ☹️

IMG_20210101_130449.thumb.jpg.0c4d64e8ae44ec9768dcbbf17c4a4ba1.jpg

Tidied up.

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Welded up.  It could be neater but is strong.

I realized that the two valance end are a mix of thin patches and filler so there will be some welding needed there too.

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  • 2 weeks later...

 

After a good look at the valance I realised that the end was mainly some odd shaped patches. It all got chopped off to reveal this:-IMG_20210102_165200.thumb.jpg.8bdbdf67697ecf3960d4321ff200703b.jpg

It had a quarter inch of filler over it before I started. I put a patch in the valance edge, then opened out the main rot hole.IMG_20210106_165613.thumb.jpg.b002b21655625685663fb9085a4edd9a.jpg

Next I tidied up the rusted brackets inside and got rid of the ragged pitted bit on the upper corner.IMG_20210109_165933.thumb.jpg.bd7b41f2a22b188a686fbbd01c77d048.jpg

Then made a patch and held it in place with intergrips.IMG_20210110_155002.thumb.jpg.b9943fb9ec2f484a5bd05212bc5cb4cf.jpg

I lapped the patch slightly under the engine bay floor by a quarter inch.

Then welded it in.IMG_20210112_133055.thumb.jpg.ab2e706a95b22e9fb7c27393c29130f0.jpg

I'm still not in practice with my welding, but the linisher is my friend. And I can always fill any small hole with weld. You can see that I added a narrow strip on the bottom of the inner wing where it laps around the valance. I treated all the bare patches and also put some Hydrate 80 on any surface rust on the inner wing.IMG_20210112_174319.thumb.jpg.5ef15df595ae3eef85b0376d59da7834.jpg

Also I took the opportunity to clean and paint the shock :-IMG_20210112_133824.thumb.jpg.7cf9f8e6b6c40254c14b78ad407ccf78.jpgIMG_20210112_154345.thumb.jpg.d9a47535e7d6bec357219ff55465a469.jpg

And the bumper bracket.IMG_20210112_170225.thumb.jpg.bdfad62f2b768071f4806d19ed84f7b1.jpgIMG_20210112_172721.thumb.jpg.a8ac9b55ceea59438ca67f664ade45eb.jpg

This work was spread over my spare time in the last week.

Next job, seam seal the repairs inside the engine bay and under the inner wing, then more zinc primer.

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33 minutes ago, Tim_E said:

This is epic. I can't imagine all this hidden rust makes you happy but the thread is very pleasing to see it get done so lovingly.

I'm not too upset by this amount of rust. And it being such an interesting car helps. I wouldn't do it for an Escort.😁

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10 minutes ago, artdjones said:

I'm not too upset by this amount of rust. And it being such an interesting car helps. I wouldn't do it for an Escort.😁

There are some who would for a mk1 or 2 Escort perhaps but ha no I agree, this is a special car needing some special attention. 

Amazing work, I'm glad you're unphased.

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Seam sealed on Wednesday.IMG_20210113_171140.thumb.jpg.cd95081bd48f571a500f3be55d2810d5.jpg

Two coats of zinc primer yesterday and this morning.IMG_20210114_174605.thumb.jpg.364ec8378f1409a3b2afb156844dd5d0.jpgIMG_20210115_120844.thumb.jpg.8bdf80f8bc4cf9db4937c402aeb4e7f1.jpg

Then on to the sills.IMG_20210115_121016.thumb.jpg.4e4098a8578ba50ed3a0c06a832b8b19.jpgIMG_20210115_121034.thumb.jpg.fc8a750822efe1e5f9b8c7742d7ccdd9.jpg

The front half was a bit crusty. On the last picture you can see the rear jacking point. I forgot to take a picture of its comrade on the front, but unfortunately the sill was holed behind it. So I cut it off.IMG_20210115_135708.thumb.jpg.9977d3bdd82a2163234f4c225f634784.jpgIMG_20210115_135858.thumb.jpg.e172f9e0e238c223555da0c7ed19ec9f.jpg

These things cost ££ so I ground the sill remains off it and treated it for later reattachment. IMG_20210115_145419.thumb.jpg.98e4760dd5408a2f92b4edaec7a328d5.jpgIMG_20210115_145958.thumb.jpg.57a201d5260ae1e2eb79677123411ec4.jpg

Then noticed the edge of the floor had some small holes.IMG_20210115_121851.thumb.jpg.87032c12547731e2f90c04e981aa582b.jpgIMG_20210115_194818.thumb.jpg.76ad879ea64aeb6be32b0ee4ef0ba7c7.jpg

And finally extended the hole in the undersill up to the wheel arch. It will make for a neater join. And there are  two lap jointed patches on the sill further back and I don't want the underneath of the car to look like a patchwork quilt. Although I feel a temptation to cut those patches off and butt joint some new ones in.IMG_20210115_165018.thumb.jpg.cf732e72084d196fb0679d49e8efa24d.jpg

The only thing holding up progress now is a lack of sheet steel. I have enough for the strip on the edge of the floor, but I need some 1.5mm sheet to replace the piece of sill(96 sills are very thick), and I'm wondering where to get it during lockdown. I have some cheques to pay in in town next week, so I may get a chance to go to the local sheet metal worker/tractor repairer to see if he has a small offcut.

IMG_20210115_165018.jpg

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