Show off your pride and joy! All Mk3 Cavaliers are welcome (please post only one thread per car)
#36496 by btcctroy
Tue May 25, 2010 9:59 pm
finally i have decidied to take my beloved cav of the road to give it some much needed tlc.

hopefully gonna get some areas sorted before i borrow it to go to pvs :thumb

ever since i bought this cav 5 years ago it has rusted in the usual places such as the sills, inner and outer arches, front and rear floor pan, chassis legs, rear struts.

think the bulk head has cracked too. so will be removing the dash at some point for a proper inspection.

i'm quite honest with the condition with my car and tbh and most people would scrap it but thats all to easy.

so this weekend i've cut the drivers outer sill off and removed the interior and carpet.

gonna get the sand blaster out to remove any surface rust

pics to follow
#36500 by Robsey
Tue May 25, 2010 10:18 pm
It will be interesting to watch the progress on this..

I suppose the decision to scrap or repair comes down to five factors: -

1) How much your want to get the car fixed.
2) Whether you can afford the cost of the work / parts
3) Having the time to do this.
4) Having the nowledge and confidence to fulfill such a project
5) Availbility of suitable parts and materials as required.

I would be just as adventurous if time and money were more abundent. :(

As is always said regarding any work...plenty of pictures are a must :thumb
#36502 by btcctroy
Tue May 25, 2010 10:50 pm
pics of this weekends efforts
Attachments
IMAG0008.jpg
started to make a repair to the inner sill.
IMAG0012.jpg
started to blast till i ran out of media
IMAG0013.jpg
light surface rust can be seen
#36510 by btcctroy
Tue May 25, 2010 11:18 pm
Robsey wrote:It will be interesting to watch the progress on this..

I suppose the decision to scrap or repair comes down to five factors: -

1) How much your want to get the car fixed.
2) Whether you can afford the cost of the work / parts
3) Having the time to do this.
4) Having the nowledge and confidence to fulfill such a project
5) Availbility of suitable parts and materials as required.

I would be just as adventurous if time and money were more abundent. :(

As is always said regarding any work...plenty of pictures are a must :thumb


yes i completly agree

1) How much your want to get the car fixed.
Too attached to get rid lol
2) Whether you can afford the cost of the work / parts
all completed by myself
3) Having the time to do this.
well never enough time thats the problem
4) Having the nowledge and confidence to fulfill such a project
its only steel and its not the first project
5) Availbility of suitable parts and materials as required.
have a genuine sill from vauxhall, floor pan repairs will be fabricated.

i have a good range of tools to make the repairs more professional

mig welder, spot welder
4hp 50ltr air compressor and all the tools you'd ever need lol
have most the gear which helps
#36517 by Robsey
Wed May 26, 2010 1:16 am
Too attached to get rid...

Yep me too! lol - had mine 14 1/2 years and 190,000 miles since I bought it.

Having all the tools sure does make the job 1000 times easier.
Having a covered garage is better still.

At least that inner sill isn't too heavily rotted, and that floor pan section is easily replaced / patched.

Wonder if you'd notice if I just happen to put my rot-box in place of yours!! lol.
Could have mine done then :)

Mine is very sound, just wants the sills doing on both sides.
Bulkhead, boot floor, floor-pan and arches are virtually rot free despite age and mileage :D
Just a scabby back door.
#36523 by btcctroy
Wed May 26, 2010 8:23 am
The outer sill is actually very easy to replace. I think of body work as a jig saw puzzle.

I think anybody who's had welding done should try to avoid plating. Never solves rust just hides it for a few years.

I always cut out rust and replace with new steel or sand blast light surface rust.

Tried most chemicals too they only delay the rust process
#36524 by Envoy CDX
Wed May 26, 2010 8:28 am
sriguy wrote:The outer sill is actually very easy to replace. I think of body work as a jig saw puzzle.

I think anybody who's had welding done should try to avoid plating. Never solves rust just hides it for a few years.

I always cut out rust and replace with new steel or sand blast light surface rust.

Tried most chemicals too they only delay the rust process


I agree whole heartedly. Just never had the option to buy welding gear, nor anywhere to work :(
#36556 by Robsey
Wed May 26, 2010 9:22 pm
Envoy CDX wrote:Yeah, if I had the tools I would have worked on mine more - just can't afford the outlay.


Aye, same here...but I was lucky enough to have a gasless mig-welder bought for me by the father-in-law three or four years ago.
I did a lot of welding on the mk2 cav, but I just couldn't keep up with the amount of rot that was there.

Lack of sufficient money and time and having to work on an exposed hill-side are my excuses so far, but I am really keen to get some work done over the next 12 months.

Hence my interest in your progress so far.

So keep up the good work, because you are being watched!! lol
#36561 by Robsey
Wed May 26, 2010 10:04 pm
Yeah, I know little bits of Chadderton, wife's friend and her brain-out partner live on Westfield Street, just off the bypass!!

If it is any help, Pentagon Vauxhall, are the most helpful dealers I've ever dealt with, especially the parts department off Park Road...great lads!! (and lasses).
#36564 by Robsey
Wed May 26, 2010 10:22 pm
Mine is a very tired, high-mileage 1994 Cavalier 1.8 LSi with the Multec CFi .

It currently stands at 216,600 miles and has been with us since 5th December 1995, when we got it at 23,000 miles (ex-hire car)

This is my WIP - with very little progress being undertaken.

viewtopic.php?f=21&t=4069
#36673 by Robsey
Sat May 29, 2010 1:22 am
Not loking sorry at all,

okay, it is missing the light, indicater and wing, but besides that it looks almost immaculate
With all your kit, I'm sure it will all be wipped into shape in no time.

Good work, great pics. :thimb:
#36681 by btcctroy
Sat May 29, 2010 10:57 am
Robsey wrote:Not loking sorry at all,

okay, it is missing the light, indicater and wing, but besides that it looks almost immaculate
With all your kit, I'm sure it will all be wipped into shape in no time.

Good work, great pics. :thimb:


Thanks never felt so good doing a job.

I.ve tried to take as many pics as I could, but also ones the might be a use to somebody doing a similar task
#36722 by Robsey
Sun May 30, 2010 12:52 am
The fact that it all appears to be going reasonably to plan makes it more pleasureable...

It is the nasty surprises, that make you ask why you bothered.

Looking back through your post,
and
Being an engineer, I understand the use of galvanising to inhibit , retard the spread of the dreaded tin-worm, but I am just wondering how good something like Cold-Galv is.

I've always been quite cynical about most chemical concoctions on the market.

I've used some of the Oxy solve type products from the Eastwood range, but I didn't feel that they did that much for rust prevention.
(The Eastwood range of products are sold by Frost Restoration Products in Rochdale).
And the fuel tank sealer....please don't ask :x

It could just be the way I have used them, but I would think that they should be quite idiot proof if you have read the bottle first...which I always have done.

Also, I thought you would be using weld-thru primer near your seams.
#36725 by btcctroy
Sun May 30, 2010 2:45 am
weld through primer generally is high zinc content spray.

its exactly what i'm using. before i actually weld the sill on i'll coat all the areas bar the seams in etch primer.

the por 15 is the best stuff to use on rust. i've had it on my chassis for a long time now its slowed the rust creep, looks nice too

www.rust.co.uk have some good products aswell.

i'm bit of a perfectionist i like my work to look near factory. i spend a lot of time making bits that are just not replaceable.

my welding has improved somewhat over the years but i'm certainly not the neatest. it has good penetration of which being the most important.

i did a bit today but the rain stopped me.

has any1 used old diesel engine oil as a rust inhibitor thinking of spraying it inside my sills after, heard that the high carbon content of the oil make it hard for rust to form, like stainless steel which is mainly carbon
#36742 by btcctroy
Sun May 30, 2010 10:13 pm
Well today i managed to get a couple more ours in on the cav. finished the inner sill, weldied in the seat beat mount, and completed the centre sill panel.

so started to align new sill panel
Attachments
IMAG0033.jpg
IMAG0031.jpg
IMAG0030.jpg

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