C.A.R.

If the rust is just bubbles, don't do anything. Just put it back together and use the Z. As soon as you start investigating the rust issues, you'll open Pandora's Box.

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:

That is not the question. The relevant question is: How much do you want to spend?

Happy New Year Everyone

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.

The HVAC fan duct was rusted away at the bottom, so I remade it:

RH sill repairs cont: Painted: Outer sill welded on: Dogleg fabricated and welded on (weld will be tided up in due course):

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...

https://www.e-go.com.au/ / Hunter Valley Express.

35mm

Reassembly is progressing at apace:

Common issue. https://www.headstuddevelopment.com.au/ can resurface it for you:

Georges Z is finally in colour! Nick & Jake have done a great job:

The RH outer sill was rusted out, so this was removed & the new KlassicFab sill was fitted up: Are these stalactites or stalagmites?

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:

@Gidgie Motorsport & @Calizedd - as it's been 2 years since the OP posted about this project, I wouldn't hold your breath waiting for it to eventuate...

Base coat applied: And the end result (Video): https://photos.app.goo.gl/BfuYECMjTYRbuCpj6

Into the booth tomorrow for it's external colour (Graeme is happy)

Bottoms of the A posts were rusted out, so they were repaired:

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:

Errrrrrrrr.... Needing replacing: L & R Outer sills. Underfloor chassis rails. Doglegs. Slam Panel. Radiator cross-member. Top Rear of Left engine bay frame rail. Inner skirt under battery tray. LH firewall where skirt joins it. HVAC plenum duct is all but gone at it's base. Pin holes in plenum floor. Rust holes in plenum top. RH floor pan requires a couple of patch's (fore & aft). Tail light panel needs sections replaced. Rust in the rear of the drip rails. Lots of pin holes to weld up. Major Accident damage to both rear quarters which will will require a lot of straightening: And that's not including the guards, doors, bonnet, hatch, scuttle... On a positive note, the sills, rails & slam panel have arrived from KlassicFab:

The body & all the panels have now been rubbed to 400g, so it's now ready for paint - which will happen next weekend. I'm determined to have it back to Mr S before Christmas!

Unusual. Normally it's the opposite of what you are experiencing after fitting rebuilt calipers... How did the brakes perform before the rebuild of the calipers? Have you changed any other parts of the braking system? Could you have the lines in the wrong ports in the master? The rear circuit has a non-return valve in it to keep the shoes up close to the drums.

Inside of the guards have had stone ship applied, and along with the inside of the doors & hatch, had a coat of colour laid down:

We have colour! Ferrari Rosso Corsa Red. My camera makes it look washed out & more white then it actually is - I can assure everyone it is very, very RED! Next the doors & guard jambs will be painted, then they well get bolted on, we'll sand the primer to 400g dry. After that it goes into the booth for top colour I'm hoping to have paint on it in 2 weeks...