Rear Wings - not a pretty sight

 

More filler than steel and hard to tell what the correct shape was or how the spats are attached.

   

For racing the boot was sealed off with sheet aluminium and any remaining gaps were filled with expanding foam

The fuel tank covers were panelled over with aluminium
 so looked a bit better than they really were.

 

The panels under the fuel tanks couldn’t be repaired but since my fuel tank is from an XJS I didn’t need exact copies so could make panels without the drain holes. 

    

Part way through the repairs, this is the view above and below.

                    

Bracing stops the body from getting out of shape

 

Bracing welded in across the door openings and
 across the body should keep it all in place when cutting
out the floors and sills. Mid way through marking
out the new floor panels

Wings, doors and boot lid off for stripping

 

Dropping these off at SPL in Dudley for stripping
and electrophoretic coating

Acres of welding

BEFORE - The rectangular steel plate is 5mm thick
and is there to brace the roll cage. That will need to be reinstated.

A new footwell instead of a rusty mess

Floor, inner sill and front wing mountings all gone!

Trial fitting inner sill

 

What is it supposed to look like?

 

The bottom of the front inner wing where it meets the sill. The cleanest section is a repair panel that needs to come off so I can repair it properly. Thanks to members of the Grace, Space and Pace Facebook group I was able to get some photos of what it should look like.

Repair panel fabricated including a captive not for the inner wing splash shield.

Looks good but no wonder they rusted. In this section the inner and outer panels taper together at the bottom and there are no drain holes to allow water to escape or air to circulate. Must remember to waxoyl this bit.

Offside just as bad!

Inner panel already welded in place, this is the template for the outer panel

Done

Master cylinders and shocks

Clutch cylinder back from Pastparts

Brake master cylinder done at the same time

KONI shock absorbers restored re-valved and re-bushed

No more rusty holes

 

Bulkhead welding completed and the joins lead loaded

The new plenum chamber where there was none! (See previous post for the before pictures)
Made from the rear quarters of a minivan and lots of shrinking and stretching. Best tool I’ve ever bought.

Channel from the heater air intake on the left of the plenum had also rotted away, now new shiny steel.

Tack welded into place ready for seam welding

Plenum under construction

Minivan rear quarter almost the same shape!

All that was left of the original plenum chamber. Must keep that drain hole clear!