SRi restoration project

[Telegram Sam]

Does anyone know anyone who has actually had their own Cav re-shelled or re-dipped or re-galvanized or whatever names these exotic treatments go by?

[humbucker]

Re-shelling: if things are that bad, then most would buy a new car. That said, some original non-IRS shells are still floating about. Acid-dipped: yes, I know plenty of people who have had this done, and I'll be making enquiries about having the same process applied to the my Turbo, but bear in mind that you'll still have to deal with corrective metalwork. The acid just neutralises the 'damage so far' and reveals the rest of it(!). Also consider the merits of soda blasting, which theoretically you can do yourself. It's an environmentally sound way of stripping the car, but that's exactly what you're dealing with - any of the above are a single process in a bare metal restoration (as opposed to repairs).

There are plenty of YouTube videos detailing the acid dip process. Envirodip and Surface Processing are the market leaders.

[Telegram Sam]

I think you've hit the nail. All these remedies and processes are great in theory but unless one has the facilities, time and expertise to put them into practice, they are just theory - unless you can find a trustworthy one-stop-shop that can take on the whole project without breaking the bank. A big ask. I may well have to settle for something a bit more modest!

[humbucker]

What say you? viewtopic.php?f=13&p=157354

[Telegram Sam]

Why not?! Provided they don't look under the bonnet I think it looks unmodified enough (lie detector disabled) though the silencer might raise an eyebrow. I still have to replace the front door decals (currently missing) with what I consider is an an improvement and I think the tailgate decal is non-standard. Would this cause problems?

[Telegram Sam]

Following the £5 K I spent on restoration in Boston 2 years ago, full inspection this evening revealed that the only way to continue is to re-shell. I will post pics shortly. >> Can anyone help with locating an SRi pre-facelift shell???

Gut feeling tells me that a new shell is a more practical route than trying to find another decent condition SRi from which to cannibalize the shell.

[btcctroy]

really a reshell?
locating a preface lift shell in good condition wont be easy.
legally I didn't think you could take the log book and use the id of your existing sri on a donor shell. The v5 belongs to the shell. I don't know how it works if you bought a brand new shell with no chassis nmber

[Telegram Sam]

This "regulatory" aspect cropped up in discussions with the restorer this evening and it seems that there are ways round it (but don't ask me what they are!). One problem at a time (what is the realistic alternative, if there is one?)

[Super89]

Cant be that bad it needs a reshell!?

[Telegram Sam]

Pics to follow, includes cracked bulkhead. That's the opinion of the expert. The alternative in his words would be a quilt patchwork job

[btcctroy]

In other words he's not interested,

[James McGrath]

Indeed. Don't take the word of one restorer. Shop around a bit and get some second opinions.

[Telegram Sam]

Having seen the evidence - there are 24 pics in total, enough to sink this web site - and had several meetings with him I'm inclined to trust what he says. I don't have the luxury of having a load of other reputable restorers within easy reach for comparison, if I did each one would have to be paid to strip the car down again (long job), quote and reassemble, and then what if I got conflicting opinions at the end of it? Given enough time and £££'s it could perhaps be patched but then looking at what's been revealed I could well believe that I'd be spending good money after bad like what happened at Boston.
Within reason I'd rather spend the extra and get a quality job for the longer term rather than end up here again in 12 months. But that all depends on getting hold of a replacement shell from somewhere!
I'll see if I can get a selection of the pics Photobucketed and you can judge for yourselves.

[James McGrath]

I don't think you're going to find a replacement shell.
Finding one 10 years ago was difficult, now it's dam near impossible.

[Telegram Sam]

I tracked one down in Ireland - would be ideal but the trouble is that it is a saloon and I want to stay with a hatch! Bonello is pondering whether he could do a conversion - hasn't ruled it out.

[colin1]

To be fair
'cracked bulkhead' doesn't sound too clever, I don't think I'd bother either

Is this bulkhead A we're talking about?

[Telegram Sam]

It is the one behind the dashboard if that is the amateur way of describing it. It is on one of the pics which I am trying to get organized.

[colin1]

It is the one behind the dashboard...

Bulkhead A then

How long has it been cracked
Impact-driven crack or corrosion-driven crack
What sort of driving has the vehicle been subjected to since and for how long
What effect will that have had on the rest of the chassis in terms of assymetric wear and metal fatigue

Coupled with the pics of your vehicle's underside that you posted up, I'd say you also have a roadworthiness issue that may or may not be insurmountable. I can't see it obviously but it feels like bonkers money to get it all square again.

That was me going for the Mr Popular vote..

[Telegram Sam]

First 2 questions: Pass
It has certainly not been subject to harsh driving that would have put undue strains on the chassis. I would therefore suspect that the crack was corrosion driven.

[btcctroy]

All bulkheads are common to crack, the Saab 9 - 3 suffered worse. They shared the floor pan.
Normally cracks close to the steering rack.
Can easily be repaired and not an excuse to scrap a car.
The floor pan could be replaced from maybe a Saab. He said he'd convert a saloon to a hatch which is a lot more work!!.
Just strip the car and get it dipped.

[Telegram Sam]

Hopes rest at present on converting the saloon shell to a hatch if Bonello confirms that this is a goer.

Envoy Gary has looked at all the pics and doubts if "patching" would be viable.

On the other hand in view of what's at stake I would not rule out a trip to Oldham for inspection???

[Envoy CDX]

Hopes rest at present on converting the saloon shell to a hatch if Bonello confirms that this is a goer.

Envoy Gary has looked at all the pics and doubts if "patching" would be viable.

On the other hand in view of what's at stake I would not rule out a trip to Oldham for inspection???

Correct, patching isn't viable. But I did say anything could be repaired too!
I think what I have said has been taken a little out of context too.

It certainly looks worse than my cav on the face of it when presented with the images Iain. Re-shelling it would probably work out cheaper was my over-all point.

I still don't understand this converting a saloon to a hatch business either, it sounds like a mountain of work when you consider the points I made earlier via email.

[Telegram Sam]

Yeh for the sake of all reading this the latest proposal is to surgically remove the rotten under section from mine and substitute from the donor shell. Sort of like marrying the two up together! At least that is my understanding of what he proposes to do and he seems convinced that that is more viable than converting the back end from saloon to hatch or the other way round.

[humbucker]

"Hopes rest at present on converting the saloon shell to a hatch if Bonello confirms that this is a goer."

Walk and keep on walking.

[Telegram Sam]

"Hopes rest at present on converting the saloon shell to a hatch if Bonello confirms that this is a goer."

Walk and keep on walking.

That was Plan B. We are now on Plan C as above!!