C.A.R. Posted December 14, 2022 Share Posted December 14, 2022 IIRC back in 2020 Daniel messaged me asking if we'd be interested in repairing the rust in his Z - and of course we were. After seeing the photos Daniel sent me if the body, some discussion around what he wanted along with budget costs was had, and so I booked the car in for the start of 2022 - although this had to be pushed back to late 2022 as I had 'project creep' from another couple of projects... Jojo from GetMyRide duly dropped the Z off in mid November, and shortly after we started stripping the Z down to a bare body shell. It was then media blasted to expose all it's sins... Lots to do... We started at the rear, repairing the tail light panel area & welding up the 5mph bumper hole on the LH side: gav240z 1 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted December 14, 2022 Share Posted December 14, 2022 Bottoms of the A posts were rusted out, so they were repaired: 260z blues and gav240z 2 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted December 19, 2022 Share Posted December 19, 2022 We elected to patch the floors rather than replace them, as the cost & time to do this on a RS30 shell is prohibitive unless the floors are completely shot. RH floor & rail were next. The rear of the floor had rusted out & was subsequently badly patched, this was cut out and a new repair section was fabricated then welded into place: Then the rail was removed and the front section of the pan was repaired: Then the new rail was installed: 260z blues and gav240z 2 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted December 19, 2022 Share Posted December 19, 2022 The RH outer sill was rusted out, so this was removed & the new KlassicFab sill was fitted up: Are these stalactites or stalagmites? gav240z, 240ZBUILTBYME, cracker and 2 others 4 1 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted January 4 Share Posted January 4 (edited) Rust had taken out the top of the LH engine bay frame rail, so I cut the top out, treated any surface rust inside the rail, then fabricated a patch and welded it into place: Notice the skirt under the battery tray? More on that next... Next job was to repair the section of skirt under the battery tray. This was not a fun panel to make - reverse curves are difficult! Where the skirt joins the firewall is also rusted out, so this needs replacing next... Edited January 4 by C.A.R. AndBir, PeterAllen, Enzo and 4 others 7 Quote Link to comment Share on other sites More sharing options...
PeterAllen Posted January 5 Share Posted January 5 Very impressive Leon. Well done. C.A.R. 1 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted January 5 Share Posted January 5 RH sill repairs cont: Painted: Outer sill welded on: Dogleg fabricated and welded on (weld will be tided up in due course): Dragonball240z, 240ZBUILTBYME, 260z blues and 2 others 5 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted January 5 Share Posted January 5 (edited) The HVAC fan duct was rusted away at the bottom, so I remade it: Edited January 6 by C.A.R. JDM-TOY, 260z blues, OdinZ and 1 other 4 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted January 12 Share Posted January 12 (edited) Radiator lower cross member was rusted out, so removed the original, fabricated a replacement & welded it in. Daniel supplied a rear closing panel - not the nicest made thing, but it wont be seen. Edited January 12 by C.A.R. Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted January 18 Share Posted January 18 LH floor rail was replaced - thankfully no major repairs to the floorpan were required. LH side sill was rusted at both ends, so it was replaced along with the dogleg: Checking the gaps are spot on: Sill, dogleg & splash-guard done: New slam panel welded into position: 240ZBUILTBYME, OdinZ, AndBir and 1 other 4 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted February 6 Share Posted February 6 (edited) The rust around the quarter windows and drip rails was next. Some of the photos are of the body are the wrong-side-up, so just stand on your head to view them properly. Focus you feck! Edited February 6 by C.A.R. 240ZBUILTBYME 1 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted February 6 Share Posted February 6 (edited) LH side: That looks suspiciously 'fat'... So graeme drilled a test hole and yep - it was fat with rust: Done: Edited February 6 by C.A.R. OdinZ, Oliphips, 240ZBUILTBYME and 1 other 4 Quote Link to comment Share on other sites More sharing options...
240ZBUILTBYME Posted February 27 Share Posted February 27 On 2/6/2023 at 9:06 AM, C.A.R. said: now tell me how to find these spot welds..... Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted February 27 Share Posted February 27 9 hours ago, 240ZBUILTBYME said: now tell me how to find these spot welds..... With great difficulty! gav240z 1 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted March 1 Share Posted March 1 Time for another update! The firewall behind the battery tray / inner skirt area was ventilated and badly pitted, so a template was taken, then a patch was made and welded in: YosemiteZed, lightmaster240z, OdinZ and 1 other 1 3 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted March 1 Share Posted March 1 RH Rear quarter panel was next - due to the extent of the damage, we decided it was easier to cut out the damaged area and weld in a new panel: After media blasting: gav240z 1 Quote Link to comment Share on other sites More sharing options...
lightmaster240z Posted March 1 Share Posted March 1 when did Jay Leno drop in ? gav240z, C.A.R., OdinZ and 1 other 4 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted March 1 Share Posted March 1 11 minutes ago, lightmaster240z said: when did Jay Leno drop in ? Last Year. He's dropping in again this year on the 1st of April. gav240z and hmd 1 1 Quote Link to comment Share on other sites More sharing options...
Administrators gav240z Posted March 1 Administrators Share Posted March 1 I'm loving the rear quarter panel repair work. Quote Link to comment Share on other sites More sharing options...
Administrators gav240z Posted March 1 Administrators Share Posted March 1 On 2/27/2023 at 10:28 PM, 240ZBUILTBYME said: now tell me how to find these spot welds..... Ask a blind woman/man who is used to reading in braille to help find the dots? C.A.R., 240ZBUILTBYME and OdinZ 3 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted March 7 Share Posted March 7 The RH front bonnet hinge mount was rusted out, so we unpicked the duct, repaired the area, media blasted the duct, repaired that, then applied some KBS rust seal, then welded it back on: Done! OdinZ and 240ZBUILTBYME 2 Quote Link to comment Share on other sites More sharing options...
C.A.R. Posted March 7 Share Posted March 7 (edited) Bar some panel beating, the body is now done finished with a fresh coat of epoxy! Now onto the panels... Edited March 8 by C.A.R. gav240z, 240ZBUILTBYME and OdinZ 3 Quote Link to comment Share on other sites More sharing options...
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