Jump to content

A Sentimental Honda Civic Restoration


Roverjoe

Recommended Posts

23 hours ago, KruJoe said:

You're doing an amazing job with this project young sir.

After doing so well with everything on the passenger side, I don't know how you mentally deal with turning the car around and setting about the whole job again, just a mirror image. If it were me, it would screw with my head too much and I'd struggle big-time with motivation.  

Though the winter. On a driveway. In North Yorkshire. Truly admirable. Keep going!

Cheers! I Appreciate it :D

Link to comment
Share on other sites

Over the Past two days ive been doing a few more jobs, Good news is all the Rear Control arms for the Drivers side are now complete! I installed new bushes for the Lower Control Arm, but kept the ones in for the others as they seemed okay, and to be honest, when they do eventually go ill just replace the arms as you can get them much cheaper than the Lower Arm. I did a bit of Tallying up on cost. If i bought all the Genuine Arms brand new they would have cost me around £700 for both sides. Lower Arms brand new are around £250 a piece. 

No description available.

 

In other news, I started to prepare for the Drivers side welding and stuff, I had to first clear out a load of crap that was in the car though. So today was mainly gutting out old crap and making things more organised so when i come to work on the other side it will be all nice and tidy. I even pulled this out of the shed today as tomorrow i will be cutting it up into sections which i will be needing for the car. Im going to cut the same places where they would if it were to be done at a proper honda place thers a few notches on the panel to indicate these cut lines so they will be cut Down the middle of the rear door and a cut just top of the C Pillar. Then it should be in two halves so that i can store it inside the car as it was taking way too much room in the shed. 

No description available.

No description available.

image.thumb.png.318ebc2a81eec4c6d7f66d7df0965691.png

 

Do note i wont be using the whole panel, only the required bits. this just being the sill and rear arch. 

Link to comment
Share on other sites

  • 1 month later...

Been a while since the last update, been busy and the weather has been crap so didnt get much done. Really hoping the weather clears up so i can crack on with more welding but for now ive been on with refurbishing the Rear anti roll bar grinded all the rust off got it primed and painted, Chuffed with the result. Bought some extra tools recently too to make my life a bit easier. Managed to get myself a Belt sander to get into the tight areas and such so fingers crossed i can use it soon :)

433417157_343114571529766_2950914512850423232_n.jpg.830f11122d30b7e8a2dd138793cbb9fa.jpg433436488_1420157788599832_5112694820103724471_n.jpg.78b9eaf341f841fa5ddcb4a7164b373f.jpg433238450_984023693053592_2535974902379023221_n.jpg.02a7fb5c25b5966707e318446ef9ab79.jpg

Link to comment
Share on other sites

  • 3 weeks later...

Another Update on the Civic!!

With this little dry warm spell of weather that is happening i decided to get a move on and use it to my advantage. The Drivers side was desperate to be repaired and i finally took the angle grinder to the rust and started cutting. 

Heres a Before photo just to give you an idea on the rust situation:

51858269288_61322e5e5b_b.jpg

 

With this being the worst side, the whole sill needs to be replaced. which seems rather daunting as ive never done something like this before. Although using the skills ive picked up from the previous side it should be a challenge which will be worth well doing for the final outcome. Im probably going to have to Brace the car as im unsure if im going to have to cut out the area where the floor is spot welded to the bottom edge of the inner sill. If so ill weld in some pieces from the floor to the upper portion of the inner sill to give the floor some strength and if needed a  bar will be welded across the pillars just in case. 

But for now im currently just focusing on the rear section of the sill. I Ideally want to get the rear of the car welded first, then progress to the front of the car where the rest of the sill and jacking point need doing. The Rover 200 and 400 Owners Club are reproducing the Front Jacking point panels which will come in handy as the Civic and 400 are the same car. Saves me making it all myself. 

No description available.

Like the otherside the backside of the sill was covered in that black underseal which i rubbed off using thinners and it came up pretty well again which is great!

No description available.

Unfortunately the rust on this side goes from the rear arch to the front jacking point. So i intend on getting the  Rear Arch done once the rear sill section is complete. thankfully i have a rear inner closing panel and some metal left over from the other sides closing panel which i can modify and fabricate in order to fill in the rest of the inner arch as it will have the same profile.

No description available.

Thankfully it doesn't look like it has gone too far up into the inner wheel arch. the worst of it is probably where the bumper bolts up into the arch. 

 

No description available.

So i got an area cut open to inspect the rust, and thankfully the upper part of the inner sill isn't as bad as i thought after a good clean up with some thinners to reveal the original Coating of Primer. 

 

No description available.

I opened it up a bit more to reveal more rust. and as you can  see the sill gets worse as you work your way to the front, and Rust has crept up between the Rear and Middle section join. Which resulted in me drilling the spotwelds out and peeling back that skin of metal to see how far it had spread in that join. If im going full on with this i may as well get rid of all the rust or it will just come back resulting in more repairs years on down the line. 

No description available.

So i cut a bit more out to reveal the panel behind and thankfully the rust hadn't spread too far up that seam. As you can see this is where the floor starts to be spot welded to the sill. 
This seam will be all cleaned up and treated or replaced if needs be. it was also nice to see that the Floor Lip isnt rusty. 

 

No description available.

The idea will be to get all the area prepared and cleaned up ready for welding. I still need to cut out the bit of rot on the inner arch where its welded to the back of the sill, Which can be shown on the photo below.

No description available.

Once thats all cut out i will then Trim up the repair panel i have made for it. This side i messed up a bit with the measurements and its about 0.5mm too big so im going to have to cut it and trim it down so that the inner sill will sit flush with the inner sill not much of an issue but still kind of annoying. 

 

No description available.

Here is the Panel i have trimmed up to put in Still needs some fettling and cutting down in some places with the finger sander so that its perfect. But i aim to get this all welded up in one piece rather than tonnes of little bits. I had to cut the lower bit of the inner sill due to my measurement cock up, 0.5mm will then be trimmed off the other piece to get the profile right. 

 

No description available.

But for now that is where i am up to, hopefully tomorrow i can get some more progress done and perhaps even some welding if all is good!

Link to comment
Share on other sites

Today was a Welding day! and i have done the small section at the back of the sill shown on the previous post with the last photo. 

No description available.

A Fabricated a new Lip for the little box section where the trailing arm bolts into and got it welded up. 

No description available.

 

Next up was the little piece that is welded from the Reinforcing plate inside the box section to the lip. 

image.png.6498c89da6490193f675141d87f95080.png

Once that was alll welded and ground flat, i then worked on getting the inner sill panel that goes over this box section. I did a few modifications to the panel i made to make it fit right adding some release cuts at the top so i can bend it into the shape it needs to be. 

No description available.

I got that all welded in and flattened the welds down. I also did the plug welds around the lip of the box section. 

No description available.

All Grinded Flat:

No description available.

Thats it all Zinc Primed and protected! 

image.png.9f9e1ffa006f2a35ad776dbaa3da0478.png

 

Link to comment
Share on other sites

  • 3 weeks later...

More Welding done recently, Thanks to a Dry Spell of weather. I Was struggling a bit with getting the lower section of the inner sill welded onto the car. i as i had pretty much no reference to go from, thankfully in the end i did manage to get it sorted then i ran out of Gas lmao. 

No description available.

No description available.

 

Safe to say im satisfied with how everything is lining up :)

No description available.

No description available.No description available.

No description available.

At this point i had Ran out of Gas so i need to get some more tomorrow so i can finish this bit off. 

 

I also did some work to these Front Fog Lights that needed a bit of a clean up. They were starting Corrode and i wanted to make sure that they were all okay inside. Heres a Before and After:

No description available.

No description available.
Still need to get some new screws for it then once thats done they should be good to go!

 

Link to comment
Share on other sites

31 minutes ago, RoverFolkUs said:

Incredible work, wouldn't like to think how much it would cost to have that lot done "professionally"!

In fact the quotes that i received when i went round places is what made me do it myself. I was Quoted around £4500 to 5000 for the Welding alone. And i dont know if thats a Normal Price these days or if that was Just a CBA to do it quote. But, im glad i took it upon myself as i would not have learnt all these skills along the way and i will have done it to a degree in which i am happy with as i know more about the car than the people at the restoration places. And them skills will most certainly come in handy when i get round to Sorting out My Triumph Vitesse. :) 

Link to comment
Share on other sites

Ayup Guys Another Update!! Got some more gas today so i could finally finish off that last bit of welding on the sill. I also just decided to plough through and bite the bullet and cut the rear arch out. The Job which im not looking forward to. But it may not be as bad as i thought!

No description available.

so the Lower part of the Inner Sill is now on Terrible mess as ive only half Grinded it down for now lmao, but i will get round to cleaning up at a later date. Ideally it was to fill in the gaps where the porous welds were due to running out of gas.

 

Next up i cut a bit of the arch out to see how bad the rust was on the lip. Thankfully its not that bad at all really i think it just looked bad when it was still all in tact. 

No description available.

I then Decided sod it ill cut the rest out making sure i dont go over the line i drew. 

No description available.

so it seems to be much worse at the top of the arch at the back where the bumper mount is, Makes sense as water ingress through the hole which the clip sits in probably caused it to rot out there first then spread. Something which i need to improve on from factory standard. perhaps lots of cavity wax, some seam sealer and a stainless steel bolt so it doesn't rust. Its nice to see the Reinforcer is all well and Solid. i will have to cut around that when replacing the inner arch, im sure i will come up with something. 

 

No description available.

Here is a more further back image just to show you the extent of the metal/rust that has been cut out of the car!! As you can also see the black panel on the floor is a New old Stock Inner Arch Section which i was insanely lucky to find. I Decided to use the Entirety of that panel as it will be much easier, quicker and neater rather than cutting and seam welding it in. 

 

No description available.

Not the Best photo as i forgot to take a before so this was taken from a Video but Heres an image of the arch before it was cut out.

No description available.

So thats what i did, Removed the spotwelds and as you can see it looks pretty good behind the seams! A Few Scabs which i cleaned up and got primed. 

 

No description available. 

Out with the old, In with the new!

No description available.

I got the inner section all Keyed with 80 Grit and put 2 Coats of Electrox on to fully protect it

No description available.

Yet again another Crap photo taken from Video, I cleaned up the panels behind, removed any traces of rust and coated it with some Zinc Weld Through Primer.

 

No description available.

Got it all Placed in and Plug Welded. Do note I have no idea why but the MG Rover Panels Are absolutely Horrendous to weld to, I think that and also the fact i struggled to see due to it being dark up in the arch led to me creating some Rather interesting Pigeon Shite welds, I think maybe 2 Plug welds were decent and the rest were crap lmao, at the end of the day, i made sure theyre strong they have plenty of Penetration so i think a grinder will sort out that issue ;)

And i dont like hiding the bad bits from you lot, I think its good to show the crap parts as well as its being transparent. Good thing is, It lines up bloody well! 

 

No description available.

And here it is with the door on! Although some of welds were poo Im really glad how well the alignment has turned out, I reckon grind them plug welds down, get it all painted apply some seam sealer and stonechip and itll be good to go! 

Here was a photo i found on one of the MG Rover Groups on facebook, This gives you an idea on how it should look like. So Pretty close i reckon, Just need to fabricate that little panel that goes in that gap :)

No description available.

 

The Next Jobs will be to fabricate the Upper section of the inner arch then once thats all done, The outer arch can go on! :)

Link to comment
Share on other sites

  • 3 weeks later...

Sorry for the Lack of Posts Recently so i thought id Catch up with what i have done. 

Ive been busy cracking on with the inner wheel arch, Id probably say this was the most challenging part of the project so far as i did not have any panels to go from, nor did i have any decent reference as most had rusted away on the car. 

No description available.

No description available.

 

It doesn't look terrible but it lost its shape the further back you went on the inner arch. 

 

No description available.

 

I accidently cut a bit too much out, However the rust behind the Underseal did creep quite far up so i wanted to make sure i got all of it removed otherwise it will just come back and a Converter will just temporarily stop it. 

 

No description available.

I Made a Panel from sheet steel cut some slots in it to allow for bending. I slowly over time trimmed it down so it would fit. I Also decided to just do it in sections so i had more control over the panel. and that allowed for easier shaping and manipulating in order for it to fit, as i have very limited fabrication tools. All Panels were created with an old Bench Vice. 

 

No description available.

As you can see here the first section is now welded in. That big hole was left over from a factory spotweld which can be later filled in. 

 

No description available.

I then trimmed the section section and welded it in. It is by no means perfect however it can be later trimmed and neatened up before the outer goes on. 

 

No description available.

Here is me Just testing the outer arch making sure that it lines up with the lip, In which it does! 

The inner Arch lip will be welded on once all the inner is complete. I decided to just do it in sections due to the limitations of the tools i have. 

No description available.

No description available.

No description available.

Next up was to Fabricate the Lower Rear section of the inner wheel arch where it juts down. This had all rotted on the Drivers side for some reason. Possibly due to all the stone hitting it. The Passenger side remains intact as it has an Arch liner there.

No description available.

The Rust had spread All along this seam at the back. I Drilled the Outer arch out, This was spotwelded to the Boot Floor. And as you can see that Lip is all corroded. 

No description available.

This was the amount of rust cut out. Quite crazy considering it was mostly hidden!!

 

No description available.

Not Perfect but a little panel was fabricated in order to make a new Lip so the new outer can be welded it it. I Managed to fabricate the Ribs in the panel which i was happy with as that should look hopefully all original once stonechip is applied. 

No description available.

No description available.

Another little section repaired where the Inner Inner arch comes and meets the Inner Outer Arch. Its quite confusing to explain but the inner is in two sections and is joined together in the middle. This picture below makes it easier to understand:

No description available.

image.png.9ed7fda2b3ca34ea3b7c761fe505d986.png

 

No description available.

The Next section was welded in This is the Outer Inner section that sticks out at the bottom The reason i did it this was was to allow me to create a shape which i can fill so that i get the inner arch accurate. 

 

No description available.

Thats the lower bit all welded in with the lip welded to it. The lip butts up to the outer arch and is spot welded along the edge. As you can see doing it like that is now creating a hole where i can then fill the rest in with another panel. 

No description available.

No description available.

No description available.

No description available.

No description available.

No description available.

Here is the Final section welded in. 

No description available.

No description available.

No description available.

 

 

This is the Before:

No description available.

This is the After with the Bumper On

No description available.

Other Side for Reference: 

No description available.

No description available.

No description available.

 

In Conclusion to the Wheel inner Wheel arch, It just needs some cleaning up, Welds flattening etc, It was probably the easiest way of doing it with the limited tools that i had at hand however the main thing is that the welds are strong and plenty of penetration was present and should hopefully look good once its sealed and stonechipped. Ill also be using some Dynax S50 for the Seams to keep rust out! 

Link to comment
Share on other sites

I also did some more Fabrication work making a new Jacking point for the Rear:

No description available.

No description available.

The Jacking points on these civics are quite crap as water just sits in the seam as they are literally just plug welded at the back of the sill, so what happens over time theyll rust and weaken then you go to jack your car up and it will quite literally snap off or bend. So when i get this welded on i will do some reinforcing welds around the edges to keep it in place, alongside putting plenty of wax between the seam once welded and hopefully that should stop it. 

Link to comment
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
×
×
  • Create New...