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

Wagon Loon · Sep 15, 2022

Although the vynal shifts well over the repaired foam. It is slightly shorter than the surrounding original factory foam .

My concern is that it may sink a little over time and use, so I'll fill it lightly and see how that feels.

Wagon Loon · Sep 15, 2022

Actually it's around the needs foam

But I will use a fine fill

Since it's impossible to get a completely flat finish between new and old

Wagon Loon · Sep 16, 2022

It's not perfect, but I'm more than happy with the result.

Wagon Loon · Sep 19, 2022

She's much better with a dash

It's taken so long getting the fiddly nights on behind, will have to be tomorrow to fit the vents

GSF 109 · Sep 19, 2022

Well done - great result!

Wagon Loon · Sep 20, 2022

5/16 bolts inside binnacle x4
Bottom 2 can just be loose, top ones need to be removed, or in this case returned

A bit fiddly have to move around the whites a bit.
But it's possible to reach the bottom two to re tighten with an extension

So the troops looking lovely, but there's a little welding/fabrication needed for the bottom shelf/airbox and that's the next job

So it's off to the old railway line for a walk with the dog now

LincolnSteve · Sep 22, 2022

That dash repair is great. Gives me hope for when my time comes. Well done.

Wagon Loon · Sep 22, 2022

Thanks.
It was not possible to have completely flat foam due to its age I suppose, so there are some undulations to the finish.
However I'm very happy with the result and am making a dog ramp which will be covered in vynal too, for my fourteen year old Jack Russell.

Wagon Loon · Sep 23, 2022

The dog ramp, ready for vynal

There's a wooden hook which locks it in place

Wagon Loon · Sep 24, 2022

Dog ramp finished lol

My dog is fourteen, and it's nice for her to be able to get in and out

It stows quite easily too

GSF 109 · Sep 24, 2022

Nice job. Hope the dog appreciates the work you put into it

Wagon Loon · Oct 5, 2022

Next part of the under dash needs some re-fabrication

It's a bit gone at the bottom

So I'm making card pattern to transfer to metal to replace what's been eaten by the tin worm, and to replace any badly corroded parts.
Most of its pretty solid though.

Wagon Loon · Oct 5, 2022

Finding some small holes while cleaning the black and red under coat off. Wonder if the base red is lead? I'm wearing a respirator anyway and swept up all the dust!!

This part is from the far left side

Wagon Loon · Oct 6, 2022

looking at the entire under dash.
Got new rubber seals from Britpart to replace the old melting ones

Made some card templates and found some 0.7mm galv steel.
The rubber seal fits fine, just hope I've got four.

Wagon Loon · Oct 6, 2022

Got a lovely separation between foam and metal of lower dash, the vynal is still bonded to the foam in one piece.

Which would be useful if just doing metal repair.

Wagon Loon · Oct 19, 2022

Continuing on with the restoration of the left most box section of the dash.

Made card patterns and cut out rotten metal, first part tracked on the bottom.

And with a lot of subtle fettling to the corner part its good to tack I will cut and weld the bottom flange separate to get a better finish

Wagon Loon · Oct 19, 2022

Still more getting to do, but it's coming together.

Wagon Loon · Oct 22, 2022

After welding up, and after some beating and slapping to correct slight distortions. Got a good fit to the original foam and try fit to car.

Just a small adjustment to the bottom hole to do and it fits well. It covers the windscreen wiper motor

It was rotten along the bottom, I assume from water leaking in, so I will put paint it with Raptor to help it resist the effects of sitting water.

no point in Worrying too much about finish as it's covered in thick foam

GSF 109 · Oct 22, 2022

Nice job there! Looks factory fresh

Wagon Loon · Oct 24, 2022

Hopefully once covered it will look better, but it's got lots of protective paint

Inside too

Thing to attend to the main hollow heater/dash tray section.

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

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