1994 Cavalier LSi C20NE (was C18NZ) Work-horse

[Robsey]

To be honest - the budget is negotiable.
No point in skimping at this stage.

[Envoy CDX]

Of Course it's repairable!
Now how much of the rust I can get out within the budget is the challenge.

Aye, know that feeling!

[Robsey]

Some update pictures of what can only be described as the reconstruction of the Cav.

Firstly - Troy told me that the drivers side outer sill was so rotted that it took only one cut for it to fall off the car.

Then the inner sill was found to be nothing but Swiss cheese.

The last few pictures show that even the worst rot boxes can be brought back to being road worthy.

There's still loads to do, but we have started on that long and twisty road.
(Well Troy has).

[Robsey]

[James McGrath]

Looks like some mighty fine work there.

It will be better than new once Troy is finished.

[Robsey]

Yes the guy is a genius, and has been keeping me updated at every occasion,

whether that is a positive thing like the completion of the inner sill and rear arch - both on the driver's side -

or the negative stuff like saying - "the inner sill is the worst I've ever seen, and looks like it has been in the sea - lol"

Cheers for that Troy.

So far I have only seen the pictures, but will be seeing the car in the metal on Monday evening after work.

I have no doubt that our Cav will be totally solid when finished.

On the down side it will also need both chassis rails replacing - so more expense.
In my opinion, it will be money well spent.

Even the swage lines on the arch repair panels will be correctly lined up.
Troy is keen to make sure everything is done 100% right.

In return I have been made to promise "many times" that I will look after the Cav from now on, rather than just driving it into the ground.
Fair request after all his hard work so far.

And people are bound to ask - Yes I plan to have the paintwork sorted too.
I am keeping the same Polar Sea Blue mica mettalic paint colour.

Hopefully have her MOT'd by December 5th at which time we will have owned her for 20 years.

Probably one of the longest ownerships in the club / forum.

[James McGrath]

Always great to see a Cav get the Troy treatment!

Troy did an amazing job with the rear spring seats on my LS. I've honestly never felt more confident about any other work done on my car.

Yeah, good luck with the MOT. I'm sure she'll fly through it.
Ah, you've got me by 1 year. My family has owned the LS since September 1996.

[Envoy CDX]

Looking great that does Rob / Troy.

[btcctroy]

Thanks for the kind words!
Robs cavalier is pretty bad tbh but like everything Manufactured it can be repaired.
The drivers inner sill is the worst I've ever had to repair, about 50 to 60% has gone.
Reference points (pieces needed to be welded in so the car doesnt move) were fitted to retain its shape.
The inner sill membrane has to be totally rebuilt, as well as others areas.
Still much to do...

[Envoy CDX]

Thanks for the kind words!
Robs cavalier is pretty bad tbh but like everything Manufactured it can be repaired.
The drivers inner sill is the worst I've ever had to repair, about 50 to 60% has gone.
Reference points (pieces needed to be welded in so the car doesnt move) were fitted to retain its shape.
The inner sill membrane has to be totally rebuilt, as well as others areas.
Still much to do...

Sheer will and anti-matter holding it together?

[Lowrider Dave]

In awe of Troy's welding skills. Last time I did any thin sheet welding I kept blowing holes in it! that was enough for me to realise I shouldn't try to repair my own cars!

[btcctroy]

It helps enjoying the task at hand. Getting the steel and welder out is nothing but a pleasure, nearly as good as a good brew and my favourite biscuits :)

[Robsey]

Agreed - I had a practice on my 1983 Camper Van conversion.
Quickly discovered that many years worth of practice were required.

That's why I gave the job to Troy.

Wife would have skinned me alive, if she thought that I had made it worse than it was already. - gulp!!

[btcctroy]

Might have to take it up as a job. Part time for now
Your have to rename me as the cavmk3 rust buster lol

[Robsey]

Hmm - I'll have to dig out the "Recommended Traders" section and post up about your invaluable welding ability.

[Envoy CDX]

Might have to take it up as a job. Part time for now
Your have to rename me as the cavmk3 rust buster lol

Look to your right Troy

[Robsey]

Only visible on a laptop - not on mobile or tablet.

[Envoy CDX]

Only visible on a laptop - not on mobile or tablet.

Ah! Well, he'll see it when he logs in on a laptop / pc then

[btcctroy]

See what!
Cheers for the supply of cake and my favourite biscuits. Top man!

[Robsey]

On a lap top, where my status shows me as an administrator,
Yours says CavMk3 Rustbuster.

There is a lot more visible on a laptop than on a smart phone.

Regarding the cakes and biscuits...
My pleasure - I am sure that those fruit shorties won't last very long though.

Possibly more supplies in due course.

[Robsey]

Well - I went to see Troy's progress.

Amazing / shocking how bad the rot had set in.
I must admit that I wasn't expecting the front wings to be off and both bumpers...
But it made perfect sense when I thought about it.
Amazingly Troy was smiling when we arrived.
(And he wasn't even aware of the biscuits at the time.)

Anyway here are just a few pics that I took tonight.

















Not for the faint hearted...
On the good side - I am advised that the passenger side is much better.

[Super89]

Brilliant work, Love how the rear arch has been repaired. Would like to have mine redone before the years out.

[planetc]

What can I add? Lot of work there, but I agree with Troy, time and money are the only limitations on what can be repaired. One thing though Troy, it doesn't matter what you do, it all changes when you have been doing it for a living for a few years.

[Robsey]

Yes, me and the missus were duscussing this with Troy this evening.

I am making the most of Troy's enthusiasm and keen eye for the details.
The pictures don't do the work justice.

Brilliant welding, and not a hint of warping or heat deformation.
Good solid consistent welds throughout.

I cannot weld myself, but I know what a good weld looks like.

What makes the job worthwhile is customer satisfaction / recognition for the work put in.

When working on cars, the look on peoples faces following the transformation from rust heap to a road legal car is what makes the job worthwhile.

Happy customers make a happy welder

(That's the impression that I got).

[Envoy CDX]

Impressed. See Rob, told ya