Update time, progress has been slow but steady, involving some necessary project creep.
Bubbling of paint on rear quarter required further investigation
Bubbles were popped to reveal rusty moisture
Went to work with a grinder to reveal bog half an inch thick in places
Bog removed to reveal solid metal, apart from a small patch along the bottom, very happy with the minimal rust. The bog was there to cover a long dent in the quarter which i managed to straighten a bit
There was some oil canning where metal had been stretched, removed it by shrinking the metal with localised heat.
Decided to strip rear to bare metal as previous repairs by PO had started to show signs of rust
Removed old lap welded patch
And replaced with butt welded patch
Repaired area where exhaust hanger had torn the boot floor
The wheel well was the next problem, it had been repaired previously with lap welded patches but other areas were now perforated, choices were to 1) delete the wheel well, decided againsted that as i wanted to retain some originality. 2) Buy a new trunk floor - too expensive. 3) Source a decent 2nd hand well or from an E21 - Hens teeth, especially in NZ, 4)Fabricate a wheel well - skill level out of my range, or 5) patch the well
Half completed patching, lots of welding but will be solid when completed and epoxy primed, total cost about $15 including welding gas (about $300 if i charged myself out!!)
After lots more cleaning, grinding, wire brushing and repeat i am at this stage
Trunk patched and bare metal spot primed with epoxy primer
Rear underfloor cleaned and in the process of wire brushing surface rust areas
Subframe, trailing arms were all cleaned and paint stripped, all in good condition apart from
One shock mounting bolt which needed replacing
It can be done without removing the rear hub, just loosen the brake back plate and you will have enough wriggle room to slip the splined bolt in.
Spraying station set up in the back yard and all subframe components sprayed with black epoxy primer
And bench assembly of subframe begins with all new rubbers. Rear hubs were in good condition so they have been left alone - project creep resisted!
Next update should see things looking alot prettier with trunk and underfloor painted, meanwhile it's back to the wire wheel!