Series 3 109 Station Wagon, full ground up resto and 88 redo careless resto driving project

Wagon Loon · Jun 19, 2020

Flux cored doesn't look so clean because of the shielding deposits, but they clean off very easily

With a very clean, no greasy ****e, wire wheel, leaving a more palatable looking weld

Decided this part at the bottom was too pitted and nasty, so made a paper former and cut a new piece.

And welded it in before going to work this morning. Cleaned it up when I got home again, because grinders are noisey

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Wagon Loon · Jun 25, 2020

Removed the brake servo and clutch from the bulkhead

The spot welds on the foot well seem to have been done in some interesting positions

To make life a little easier I cut much of the foot well out.this also made for better access to carefully remove the Parts of the old of foot well.

The inner upper corner was a proper pain to remove but eventually after it fought me for a couple of hours it came out cleanly

It feels great to have got it all out, the temptation was to cut the corner, cut and weld to the part stuck in.

Wagon Loon · Jun 27, 2020

Trial fitting the repair panels

Separated the reinforcing internal foot well panel which gives extra support to the pedals. It seemed strange that YRM's panel didn't incorporate this, but perhaps their repair panel is of a thicker grade steel than the original.

Also perhaps this is why the YRM footwell has no finger groves pressed in.
But what I have recovered is a bit pitted on the inside so I am making a pattern and will make a new one from galvanised steel

Wagon Loon · Jun 30, 2020

Made a card template from the replacement footwell, as some bolt holes were drilled in different places.

And after cutting and shaping

Needing to do something about the bottom of the bulkhead tunnel side

Cut the bottom off where it is corroded and weak made a cardboard pattern, transferred to galvanised steel-cut and shaped

So that's the Off Side repair panels made and ready to be fitted and welded in with plug and butt welds, which sounds a bit fruity lol.

rob_bell · Jul 1, 2020

Wow, this is looking good

LincolnSteve · Jul 1, 2020

Really lovely work.

Wagon Loon · Jul 2, 2020

Thank you so much for your encouraging words.
I'm back at work and Daughter's back from Uni and I'm taking her for driving lessons so not getting as much time in as I would if I could each day.
However been butt welding the bottom repair section I made today

Which is starting to take shape

But tomorrow I go on holiday, so am hoping to finish the structural welding and after removing the bulkhead finish it with U-pol 2k car paint. Then I can take the engine and gearbox out and get on to the chassis repairs.
I will be trawling here to learn how to do the transmission and engine and refurb of the axles. Hopefully with the bulkhead and engine removed access will be better, and I have so much to learn. But I'm really looking forward to it all.

Knappster · Jul 4, 2020

Looking good!

Wagon Loon · Jul 4, 2020

Thank you,
Hoping to get the metalwork on bulkhead finished next week.
Dingbro want me to take some panels in to get a good paint match for the marine blue.
I wonder if there is a paint code out there somewhere, or is every blue series three a slightly different colour lol

Wagon Loon · Jul 9, 2020

H

Have to start with the foot.
After having everything fitted and screwed together with roofing bolts, it all had to come apart again; because I have to weld on the new foot first. At least I know everything fits, or will.

Once the foot was welded the other panels were fitted and screwed together and I started plug welding everything for about a day lol.

Next to get fitted was the wee brace and support panel I made to replicate the original layout.
Having fitted a new reel to the flux cored mig and been up patching some leaky bits on the garage roof, it was lovely to have clean dry welds happening.

Wagon Loon · Jul 9, 2020

This tunnel panel has rotten ends, so I'm going to make card templates and replace the rotten bits.
The ends are originally made of the parts, don't know why

Sort of like this.
So that's a job for Infront of a film later to make card patterns.
Most of the panel is solid and I've seen quite a few variations. Besides it's more fun and rewarding to make the old knackered panel like new, and it's mostly good. Maybe the ends went because they welded bits on to attract rust

But the top part's pretty good

GSF 109 · Jul 9, 2020

Looking good. I did the same repair on my bulkhead to tunnel diaphragm. Tricky repair, but you will manage fine I’m sure!

Wagon Loon · Jul 10, 2020

Thanks GSF 109,
I did have a look online for new ones, but they all seemed to be ever so slightly different.
So since we had lovely weather this morning and I'm on holiday, what better than to make some templates over fresh coffee

And viola with some plasma cutting, flappy grinding to clean edges, welding, more grinding, more welding and grinding smooth.
One end is replaced and galvanised to booty

Wagon Loon · Jul 11, 2020

And wirh a lot of shaping because of curves formed on opposite directions on the N/S

Can't wait to get some acid etch primer on to protect it.
There is some minor non structural corrosion which I would like to cut out and replace in the centre part of the bulkhead. But now I can remove it for flatting and finishing and finally painting

Wagon Loon · Jul 11, 2020

LincolnSteve · Jul 13, 2020

That's lovely work again. Also helps me a lot. The ends on mine are so far gone I wasn't even sure what shape they were supposed to be. Good to know what they should look like.

Wagon Loon · Jul 13, 2020

Getting the N/S to fit round the footwell inner was challenging, but I just kept re fitting it and reworking until it was a really snug fit.
There's so many places for water to get in and trapped on these landies, but you have to love'em lol.
Was looking at the new Defender and it's special extreme sport equipment pods lol.
I can't imagine chucking a sheep in the back of one of those.
So I suppose their the masculine equivalent of the rangerover evoke. Funnily enough both designed by the same bloke.
A nice looking SUV, but is it a Disco4 ?

LincolnSteve · Jul 13, 2020

Maybe this is the new utility vehicle to have now that Land Rover don't make one. https://ineosgrenadier.com/

Wagon Loon · Jul 13, 2020

It got a kick of undercoat

Wagon Loon · Jul 13, 2020

Yes I watched this and thought Land Rover missed an opportunity here to go back to building a proper no nonsense car.

It looks like a great car, and almost a clone with useful improvements.

Series 3 109 Station Wagon, full ground up resto and 88 redo careless resto driving project

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