1995 Opel Astra Saloon. Gaan voort met die roes herstelwerk.

[JMotor]

Giving this car it's own thread.

Helps me keep a record of what work/misery I will be going through.

I'll keep the story short. This is my Opel Astra 160iE Saloon, I've owned it for about eleven years now. It's an South African market only model of the Astra F, so rare in the UK. This was bought new by an life insurance company in South Africa. Came into the UK in 1999 with the gentleman who had used it when he worked for the company.  

 

Bought with no MOT and a buggered heater matrix. Sorted all that and got it back on the road. Used it for a few years on and off.

Did lower the car and fit some wheels. Same style wheels as the Vectra Supertouring ST200. Left the car original otherwise.

Found a hole in the sill one day and went for a closer look. Oh dear.

So did what any sensible person would do. Shoved it in various corners and ignored it for ages.

I've made time for this car now. Plus I'm fairly confident I can fix this car, the Corsa I done turned out not too bad. 

[JMotor]

While I pondered how to go about fixing it.

I did need something to repair this mess with.

Few years ago me and a friend found a cleanish shell to donate it's sill sections.

At the time I didn't feel bad about doing this to a fairly clean car. It was already scrapped and Astra's were still ten a penny. Not now!

Anyway. Started picking apart the section.

Much cleaner! Then I threw this into the corner and forgot about the car. 

Spent all my time looking for other panels too. As I found more wrong with it. Panels aren't easy to find and now not cheap either.

[JMotor]

Yesterday was the first proper amount of time I put into this car. 

Time to see how bad everything was. 

That jacking point is done!

Removed more of the outer sill. I have learned to cut slightly more out to get better access. Still have more sill to trim for when I fit the new outer. Using a genuine panel as it should have a much better fit over a pattern one.

Now I can see what I'm doing. That membrane thingy isn't as rotten as I thought.

That donor section should give me everything I need to repair the rot. 

[warch]

  On 02/09/2024 at 11:41, JMotor said:

Spent all my time looking for other panels too. As I found more wrong with it. Panels aren't easy to find and now not cheap either.

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Oddly I'm not having the same issue with the Mk3's older brother, perhaps the Mk 2 has more of a following.  All looks very familiar though, especially the crunchy sill issue.

[JMotor]

  On 02/09/2024 at 13:43, warch said:

Oddly I'm not having the same issue with the Mk3's older brother, perhaps the Mk 2 has more of a following.  All looks very familiar though, especially the crunchy sill issue.

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Very much does, so many layers of steel. Luckily it looks not too difficult to either fabricate something or scab sections off my donor piece. 

Kinda typed that without thinking. I should of said certain panels are hard to find genuine or aftermarket. Sills and rear arches are still easy to get. The ones I need are harder to find, like the inner fuel filler area for example. The best place I've found for the more tricky to find stuff is in Europe.

 

[grogee]

Good effort @JMotor. I like to see a motoring curio saved.

I was trying to work out what engine the 160 would be - 2.0i? 16v?

Did the UK get the saloon? I can't even remember any more. 

I like how we're seeing all these mad SA spec Fords and being assured there's no rust because it's an SA import. Did yours go rusty because of its time here in Rainy Island? 

[Soundwave]

  On 02/09/2024 at 14:48, grogee said:

Did the UK get the saloon? I can't even remember any more. 

 

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We did indeed get the saloon, although not in this spec.

And like all hatch-based saloons in the UK from the mid-90s onward, about three people bought them.

[warch]

The Saffers also got a C20LET version of the Astra with the superb 204hp engine from a Cavalier/Calibra Turbo, front wheel drive and a limited slip diff (the bastards). I'd love one of those, especially in saloon (sedan) form so I could convert it into Dennis and Mabel's pride and joy with a few National Trust stickers and a various other giffer trinkets.

[JMotor]

  On 02/09/2024 at 14:48, grogee said:

Good effort @JMotor. I like to see a motoring curio saved.

I was trying to work out what engine the 160 would be - 2.0i? 16v?

Did the UK get the saloon? I can't even remember any more. 

I like how we're seeing all these mad SA spec Fords and being assured there's no rust because it's an SA import. Did yours go rusty because of its time here in Rainy Island? 

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Thanks. Very attached to this car and it is quite rare. Was apparently the only one on the road at one point. A few made it to the UK, but most were broken up.

Aye, this one is a 1600 8v. So the model code is quite simple. 160 stood for engine size, i for injection and E for executive. 

There was Saloons sold here. Rarest one would be an SRi one but those could be all extinct by now. 

Yeah I reckon it's not weathered our climate so well. The side skirts do trap dirt and damp sadly.

[JMotor]

  On 02/09/2024 at 15:10, warch said:

The Saffers also got a C20LET version of the Astra with the superb 204hp engine from a Cavalier/Calibra Turbo, front wheel drive and a limited slip diff (the bastards). I'd love one of those, especially in saloon (sedan) form so I could convert it into Dennis and Mabel's pride and joy with a few National Trust stickers and a various other giffer trinkets.

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Very correct.

The 200tS. One made it to the UK and I'm good friends with the current owner. It's also being restored as well.

Got to perv at it many years ago. 

[Jenson Velcro]

Yes as said, saloons definitely sold in this country. I had a K reg one as a company car, along with several other fellow employees at the time. All ours had the 1.7 ( non turbo) Diesel engine and were totally lacking in any acceleration. All were thrashed mercilessly though.

[Lord Sterling]

Nice! Fatha_Sterling rented an Opel Astra CD saloon in Syria years back when we visited, this would have been about 1999/2000~ish.

One year we had a maroon one and the next year a blue one. I thought they were great cars.

Was like this with the same alloys.

[New POD]

  On 02/09/2024 at 15:10, warch said:

The Saffers also got a C20LET version of the Astra with the superb 204hp engine from a Cavalier/Calibra Turbo, front wheel drive and a limited slip diff (the bastards). I'd love one of those, especially in saloon (sedan) form so I could convert it into Dennis and Mabel's pride and joy with a few National Trust stickers and a various other giffer trinkets.

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That would be the TS200 

[Marshall2810]

Got a lot of love for the mk3 astra and commend anyone who is willing to put work in to save a rare example of GM 90s loveliness. Thank you @JMotor 🫡

[Austin-Rover]

That looks lovely, and great to see you putting the work in for a long term project and such a rarity too. I have my own Mk3 Astra saloon that has been part-way through a stalled restoration for many years! 😆😀

[horriblemercedes]

  On 02/09/2024 at 17:01, New POD said:

That would be the TS200 

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200tS

[JMotor]

  On 02/09/2024 at 16:46, Lord Sterling said:

Nice! Fatha_Sterling rented a Vauxhall Astra CD saloon in Syria years back when we visited, this would have been about 1999/2000. One year we had a maroon one and the next a blue one. I thought they were great cars.

Was like this with the same alloys.

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  On 02/09/2024 at 17:51, Austin-Rover said:

That looks lovely, and great to see you putting the work in for a long term project and such a rarity too. I have my own Mk3 Astra saloon that has been part-way through a stalled restoration for many years! 😆😀

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Unnggghhh.

I might need a minute. Just to get over the sheer filth of seeing these Saloons! They have aged very well.

@Lord Sterling CD really was top tier spec for a Euro Astra. They had a very nice velour interior. I had a blue hatch CD many years ago with the blue interior. 

@Austin-Rover Oooh a GLS one! With the correct wheel trims too. Again had a GLS 'loon as well. Unfortunately it and the CD I had were both very much kippered with rust!!

So I hope you manage to finish it someday 🙂.

I've owned a lot of MK3 Astras over the years and this one just sets off my nerdy senses. They are quite different in a lot of ways to a Euro built car.

[stuboy]

shame we never got a hot saloon in the uk for the astra

[Split_Pin]

I always liked these unusual sporty MK3 saloons and they look great in this colour. I think I used to know the owner of the 200ts frkm my Club Vox days but he had a hatch model back then, which was many years ago.

[JMotor]

Forgot you were a member of ClubVox a while back. It's still the same guy who has it now.

He did have a five door that met a not so nice end a good while back. Still mucks about with MK3's yet.

Oh! Found some more pictures of when mine and his Astras were together. With a guest appearance from another pals car. He converted his four door saloon to a two door.

 

I really want to replicate these photos again. 

[JMotor]

I have an update! 

Ahh bollocks! I cut some more inner sill away. Found a nice pile of corn flakes sat in the end of the chassis leg.

Then cut another small amount off. The rot has crept into the floor and rear seat pan. 

What action to take now?

Yep. I'm back to the idea of replacing the inner sill for the 1346th time. Well I have the panel sat already. My logic being that is that drilling spot welds out will be LESS miserable than chopping rot out from awkward areas.

Once the inner is chopped out, I should have plenty of room to repair the surrounding areas and the chassis leg. 

Something I hadn't mentioned. Not sure how, I managed to find the original owner of the car! I'm shall be keeping him updated to the progress too. I'll ping an email when the sill is less frightening to look at 😆.

[JMotor]

Made a start on picking out the rotten inner sill today.

Front seat rail removed first. Glad I done this as there is some surface rust to treat.

Now had access to all of the spot welds on the inner. Cracked on with that. Sorry for the crap picture.

I have managed to get towards the rear of the panel. Should have it out tomorrow. Don't regret taking this route now, as I'll have room to fix other rusty sections with decent access. 

As a precaution, I have welded a brace in. These shells are actually pretty stiff. Buuuutt I don't wanna test that theory either! 

[Split_Pin]

Good robust work there man. Looking forward to hearing about the original owner!

[JMotor]

  On 28/12/2024 at 20:35, Split_Pin said:

Good robust work there man. Looking forward to hearing about the original owner!

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It's a pretty boring story so far. 

He obviously had it from new. Bought it from the company and shipped it to the UK when it was four years old. I happened to find his name from an old document I found in the handbook. I took a chance from a LinkedIn profile 😅 and found the right fella! He has since moved out of the UK. I don't want to reveal anymore and that's basically all I know. I am keeping touch with him with the progress tho and he seems pleased (albeit a little surprised) that it's still around. 

Actually that document is the official letter from the manufacturer for exempting it from Catalyst emission tests. Because at that time these cars were never fitted with Lambda sensors or Catalytic converters. Still fuel injection but with a little box of tricks hidden to keep the ECU happy.

Another random fact. Sir Michael Edwards of former BL fame was a Director at the Delta Motor Corporation when this car was built! Only know that as at the bottom of the letter his name is mentioned.

 

[JMotor]

Inner sill out. 

Surprised at the amount of rust that was hidden. Some of the panel is still to be removed, I just wanted the bulk of it out.

Here it is with the new panel.

To finish with a couple of photos of the hole it left behind.

Floor and chassis leg aren't looking so hot. Definitely not beyond hope though. Might get away with some localised repairs and a crap load of cleaning with some phosphoric acid and wire brush.

I'd like to make all this solid before welding the new inner in. 

[JMotor]

Another bit done today.

Cleared the remaining inner sill off. Finger file made quick work of that.

Tried to work out what should be my next job. Figured I'd remove this section next. Let's me see more of the chassis leg and the floor.

 

Typical it's got car pox in that too. I'll come back to this later. Thinking about making a new section just to be rid of that grot.

Made a start on patching the floor. Some sections got mangled and others was a little too rusty for my liking.

Was a nice feeling seeing some fresh metal back in. Easy lead in to get more done. 

 

[JMotor]

Little more progress.

Floor to inner flange repaired, derusted and drowned in Bonda primer. Took a while to get here. Usual, spend ages and it still looks no different. I didn't even bother taking a better picture of what was done.

This area was quite rusty. But it appears to be cleaning up fine with repeated use of phosphoric acid and a wire brush. Just one pin hole appeared, quickly fixed. 

Moved on to the new panel. Ground off the protective coating and painted several coats of primer on where I won't be able to get to after the panel has been fitted. I don't want it looking like the old one I just hacked out.

Maybe next weekend I can at least start welding metal back in.

[JMotor]

I was happy to have this piece in. 

Cut from the donor section and grafted into the car. It's damn clean and has saved me a heap of fab work. 

Need this in to clamp the inner sill and help set its position. Various paints and rust prevention can also be carried out before access is closed off.

I had a quick go over with the welder and more than happy with the welds I was getting. Good penatration with not too much material to knock back.

[JMotor]

Another day down at the shed.

Squeezed the inner sill in and started getting it welded in. 

Not gone crazy. Just welded in certain spots to hold it in place. I still have to make adjustments yet.

However it is nice to see more fresh metal in and less of the rot.

It won't be long before it's fully attached to the car. Really happy with how it's turning out. 

[JMotor]

Due to the storm at the weekend, there was no power at the unit.

Was nice to have a break from doing any car work. Then started to think about the next task to tackle on the Astra.

Rear chassis leg or move into the rear arch tub and filler neck area. Whatever way I went, I bought some sections to help with filler neck.

Did find a whole inner quarter panel in Germany. 

 

Came very close to buying it. Cost stopped that, £350 before duties and tax. Aye, no. I'd be only picking what I wanted from it and the above repair panels would do the same job with some sheet steel to fill any gaps.

Rear chassis leg will need sections making from scratch. Turns out the R/H one I'd already bought is different between Hatchback and Saloon where it meets the inner sill. Oh well! I'll look to selling that at some point.