Rear End - still to do

A quick round up of everything that needs doing before the back end is done:

Finish up filling and shaping the rear sills
Weld a couple of patches to the wheelarch lips (they're good enough to not need replacing outright)
Finish up the boot area and paint (at least in primer for now)
Go over the underside, chase out any surface rust
Apply POR-15 system (marine clean, metal ready, POR-15, top coat)
Fill and finish fuel cap area
Buy & fit new fuel tank
Get suspension parts powder coated
Paint axle (POR-15 again)
Shape and fit rear brake lines
Fit axle and rear suspension (new polybushes, old springs and shocks for now)
Refit handbrake and cable (no actual brakes until the car is nearly road-ready, to prevent seizing/binding)

That looks like a lot! :o

Sill panel at last - Part 2

So with the inner sill all fixed and shaped the previous day, the Sunday was all about fitting the panel.

First test fit:



And after welding in place:





Note the neat, professional quality spot welds. :-)
In spite of the mess, they're strong as anything, that panel isn't going anywhere.

A bit of grinding and filling later:



A spot of primer:



And I'm happy with that. It's not perfect yet, but it's close. Just needs a couple of spots filled, then the inner side and the wheelarch bit to do (which, bizarrely, I don't have any photos of).

In the time between waiting for filler and primer to dry, I kept busy with a couple of other bits:-

The wheelarch (now finished, yay!):



The cap for the top of the N/S damper mount:









I like these little side jobs, they're good for when the filling and grinding gets too much, but you don't feel like you're just sitting around doing nothing.

Sill panel at last - Part 1

After a bit of a longer wait than I'd hoped, the sill panel finally arrived last week. :-)

So, with some good weather to play with, I headed down to get started on rebuilding the sill. I'd forgotten what a mess it was, I'd been waiting for the sill so I had a template before I started the job. Here's what it looked like to start with:



And the new panel, ready for fitting:



So after a bit of deliberation as to how to start, I skipped the planning and just got busy with the angle grinder. :-) Several minutes later, all the rusty metal was gone and I got started with the new patches to measure, cut and weld. Unfortunately in the excitement I forgot to take any pics until I'd done a fair bit. Still, I got as far as this:



A few panels cut and shaped later:











And the finished result:





And after a bit of filling and priming:



That was where I left it on Saturday.