My god the time flies, got time on my hands at the moment so here goes, two years of updates.
So with the inner wheel wells sorted it was time to get all the rear suspension off the car and start work on the rear chassis legs. Both legs showed signs of old repairs and they were just patches over patches so the rot has just carried on, time to cut out the rot.
New chassis legs are just not available anywhere, even my contacts in Europe could not locate any so I'd need to re-build using 2.5mm plate for the inner sections and 1.00mm plate for the outer sections.
The first job was to find out how far the rot went so disc cutter in hand i started cutting the outer skin off and removing it from the inner section until i hit good inner metal. I got the outside & underside outer skins cut back and then attacked the inner skin starting with the lower section first.
Now this wasn't the easiest part to make and it took an hour or so to get the profile correct by hand and once it was the correct shape i welded a couple of bridging pieces into each end of the leg then seem and plug welded the new part in place. This was then repeated for the two inner side section and the outer skin. The right rear leg was i bit more involved as i had to remove the spring seat plate as the rot had got underneath that.
This is the hole i started with
Inner & outer skins removed
Inside view of the leg, This will be pumped with a couple of litres of cavity wax in the end
Old inner skin removed
New inner skin, zinc coated ready to go in. You can't see it in the pic but the narrow end also has a longways kink in it as well
Under side fitted
Better View
Outer section all welded in
Outer skin of the right rear leg removed
Spring seat plate and outer skin removed
One of the repair section ready to be cut out.
Next on the list was the inner wall of the spare wheel well. The seam had started to go so that was marked out and repair section made up
Marked ready to cut
There's a hole in my wheel well
New Panel
Fitted, welder has having a hissy fit at the time so welds not as tidy as normal but cleaned up ok
Finished view from the inside all painted
Thats it for now
Andy