welding project Juular's Scandi Noir. Volvo C70, 240 &122. Worst job ever.

[juular]

Long update klaxon.

Sorted the welder. Well, it sorted itself by running out of wire. I bought some new stuff - SIP as it was all that was available, and the machine is back to normal again. Maybe the end of the old reel was a bit corroded or the inside of the roll is harder to feed?

Cracked on with the 240. I have another incoming rustbucket that I have no need or space for, so I'm doing a bit of a marathon. The latest purchase is also going to need a lot of welding.. 

I cheated a bit with the rear arch by welding the inner to the outer.

I flattened that then welded on a lip.

While it's not technically correct it still looks original and in theory should be less prone to rust as there's no more double skin.

Tidied everything up.

 

With a skim of filler it will look original hopefully.

That marks the point where the passenger side is complete. I'm well past half way though, and I reckon the other side will only be a week or so as I'm focusing some time on it.

Tidied up some surface rust.

Sorted the fuel filler and breather area.

Made a start on the other side. It's similarly knackered.

I'm not going to mess about doing keyhole surgery on this side as I have a full replacement outer sill. So the plan is to take the whole outer off, rebuild the inner then plug weld the new one on. Should take a fraction of the time.

Started by taking the doors off and bracing the openings with some angle iron.

 

@Lacquer Peel was the skilful spot-weld drill, hammer and chisel operator for this job.

Something has been living in there..

 

 

The B pillar base needs a bit of tlc.

Inner sill is a bit knackered in places.

Chipping away at the rust.

 

Nu metal.

Rusty outrigger.

Here's one I made earlier.

More to follow soon.

[juular]

Almost forgot the teaser shot.

Just realised it's roughly the anniversary of me getting my first Ovlov, so this is good timing.

[danthecapriman]

Top work fella’s. At this rate it’ll be in for MOT this time next week!

[Minimad5]

Absolutely smashing it !

Good work on the fabrication too

[big_al_granvia]

Newbie, Austin landcrab????

[Saabnut]

Fantastic work! I nearly bought this to go with the GLT estate I bought from the same estate but decided one rusty Volvo project was enough. It is a good job I didn't as it would be bean tins by now! So pleased to see it being done!

[juular]

6 hours ago, big_al_granvia said:

Newbie, Austin landcrab????

Close with the era. But not right!

[juular]

47 minutes ago, Saabnut said:

Fantastic work! I nearly bought this to go with the GLT estate I bought from the same estate but decided one rusty Volvo project was enough. It is a good job I didn't as it would be bean tins by now! So pleased to see it being done!

Do you still have the red estate?

[GMcD]

My guess:

 

[Saabnut]

2 hours ago, juular said:

Do you still have the red estate?

Yes, I do. Fitted new tyres as the old ones would not hold air so I can move it around. The plates required on the sills ended up needing new sills, so it was put on the back burner for a while. Hopefully this winter.

[juular]

17 minutes ago, Saabnut said:

Yes, I do. Fitted new tyres as the old ones would not hold air so I can move it around. The plates required on the sills ended up needing new sills, so it was put on the back burner for a while. Hopefully this winter.

I'm hoping perhaps a joint reunion in Arbroath for the PO might be a future thing? He seemed really keen on seeing the car again.

[juular]

2 hours ago, Gerrymcd said:

My guess:

 

When did Nike start making cars? 🤨🤣

[davehedgehog31]

Good work that man, what an effort. 

[320touring]

2 hours ago, Gerrymcd said:

My guess:

 

At you saying he's bought a big walloper or that New Shepard's next launch will be from the central belt?

[GMcD]

57 minutes ago, 320touring said:

At you saying he's bought got a big walloper or that New Shepard's next launch will be from the central belt?

😂 ftfy.

New Shepards logo should be more like:

. Work on the 240 looks brilliant as usual 👍

[juular]

Lots done today. 

Finished welding on the outrigger.

Driver's side floor completed.

Rest of the floor repaired.

Inner sill complete.

 

Just a small bit left at the rear jacking point to fill in.

Once that's on, it's just the outer sill to glue on - then the rear arch and that's it!

[Cord Fourteener]

Looks lovely!

[Scruffy Bodger]

Good to see this coming along now. You're really lucky if you can get a full sill to spot back on. I've just had to do both sides of a Transit Connect. All I was provided with were two bent sections, that meant that effectively you've got 6' of pure weld to do on both sides, not including the 4' of repair on one inner sill. Thankfully I managed to do it without warping the shit out of it either.

https://workshopping.co.uk/chemical-products/aerosols/paint-aerosols/primer-aerosols/sealey-scs034s-grey-zinc-primer-paint-500ml?gclid=EAIaIQobChMIiaehraTv8gIVgeJ3Ch0DrQnnEAQYCCABEgJaT_D_BwE

I used that stuff on the inner bits before welding back on. I found you can weld thru it no problem at all and it doesn't make the welds porous, even plug welds. I bought it locally, dunno about that source.

[juular]

The new* car is on its way and should be with me tomorrow.

240 update:

Inner sill at the rear jacking point repaired.

 

Inner sill prepped by grinding down some welds, knocking through the spot weld holes and then painted.

The new outer sill was offered up, marked and cut to fit the remaining sections.

 

Holes drilled in the lower lip for plug welding.

A coat of weldable zinc inside.

Positioned, adjusted, clamped, then tacked in.

Then seam welded in.

Then plug welded at the flanges.

I mistakenly thought the sill panel included the A pillar base but it doesn't. 

It was getting dark, but one last job for the day involved pickling the rusty B pillar base in citric acid.

 

On to today, the weather took a bit of a turn so I had to build a temporary garage.

To be honest it's WAY nicer to work in here than out in the hot sun with the blinding light setting off the helmet darkening constantly.

Rebuilding the pillar base essentially the same as I did for the other side.

Start with the flange.

Then build it up.

 

 

Needs filler but confident it'll look ok.

Next the section at the B pillar with the missing outer section needed flattened and prepped.

 

The pickling worked well but a small hole developed.

 

Zap.

 

Primer

Some filler required but generally very pleased with it.

Since the weather turned to shit I put the doors back on.

The end is tantalisingly close now!

[Minimad5]

@juular Your welds are looking so much neater, and as always the fabrication is top notch, keep up the good work.

I put off P4 graft today due to it seriously pissing it down 😅

[juular]

54 minutes ago, Minimad5 said:

Your welds are looking so much neater

Thanks, I think I have been battling with corroded wire for ages!

[Scruffy Bodger]

Looking loads better now the welder is playing ball, and a nice fit on the panel/plates. Did you blow all the bits of rust dust out the liner?

[juular]

Small scab..

You know where this is going right?

Let's poke the outside area!

Hooray!

I honestly thought this bit would take me an hour tops, but it took me an hour and a half just to get this bit of board out of the way of the welding area.

The headrests have to come off, the rear seat back out, and too many impenetrable clips and things.. over engineered to hell and back.

 

Now on to the last welding job. 

The rear arches aren't pretty.

 

Cut the lip off.

 

 

Cut the rot out of the inner.

Snipped the worst bits of the outer away.

Made some citric acid gel and glooped it on as there was some mild pitting left.

And a major milestone.. the very last bit of rot is cut off the car.

Just to weld in new metal to those holes and the welding, at least on the car itself, is complete.

[juular]

The welding on the 240 is finished.

 

 

Behold. The last little bit of metal going on the car.

Flattened down.

 

Keep your work area clean folks.

I had a few of these.

 

[Ian_Fearn]

Absolutely brilliant. I know how much perseverance it takes to do these sort of projects. 11.5/10.

[Minimad5]

Brilliant work that man !

Now cover the lot in Vactan, Vaseline and anything else that will act as a water repellent 😅.

[juular]

That's the plan! Currently everything is in zinc primer but the next job is to shovel in seam sealer, cavity wax and decent paint. Then clean up the suspension and refit it. Much eggsite.

[Split_Pin]

Hurrah! 

Good to see you weren't put off by that rusty Celica  all that time ago!

[juular]

26 minutes ago, Split_Pin said:

Hurrah! 

Good to see you weren't put off by that rusty Celica  all that time ago!

 

[Split_Pin]

It's like a tide of rust!