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Old 07-05-2017   #31
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Re: My next project

A very productive day today.
Removed the rear screen & 1/4 windows - cut the rubbers out so as not to chance breaking any glass.
Stripped the front bonnet area of tank & all components and removed the complete wiring loom, switches and speedometer.
Also decided to remove the roof. quite easy really.
Remove the sunroof, 2 bolts holding the frame and the small nuts holding the rear rail - most of which snapped off.
Then there are 2 10mm nuts inside the roof rail, the washers all fall into the roof channel so don't know if I will see them again. Then undo the screws along the bottom of the rear air grille and then it comes off with a little leverage. The roof is rather rusty around the rear screen aperture and also on the 2 front corners. All of which can be repaired but the inner channel around the rear screen is going to be the difficult one.
Amazingly there is little rust if any on the roof rails now the roof is removed.
I tidied up the inside a little and found my D had been a home to a little rodent in its past. I also removed some of the sealer and sound deadening. This has now exposed the full extent of the impact damage to the right rear. Someone has had a go at repairing the 1/4 panel but they have left the damage to the rear floor, inner wing & wheel arch. Also now the roof is off you can see there is a larger gap between the inner 1/4 panel and the rear seat panel.
I'm going to attempt to give the rear end a pull but I think I am going to end up removing the 1/4 panel, unpicking the inner panels to remove the strength then I should be able to straighten everything up.
The front end has also been repaired with a new front panel but they didn't repair the inner front panel which is still badly damaged and corroded. I'm also going to give the front a quick pull as the front wing has closed up to the front of the door. There's not much strength in the sills so I need to be careful I don't pull the car apart.
I'm surprised how some of the panels are so much better condition than my L was but sadly the accident damage is going to mean a lot of bodywork repairs to be carried out. So watch this space for some serious panel work and welding going on.
Just not sure when yet!
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Old 07-05-2017   #32
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Re: My next project

So removing that roof is that something specific to the D Sean? Never seen one removed before. Could you go transformable with the full sunroof?
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Old 07-05-2017   #33
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Re: My next project

Oh yes!
This was the design for the N & D.
I'm not going to quote models etc, I will leave that to the experts! but there was the option for the full transformable model or the with roof. I think on the D's they were all fitted with the roof.
I just need to remove the centre brace and then buy the full roof and frame.
The original sunroof frame mounts aren't used but there are similar points halfway along the inner roof rail where 2 captive nuts need to be fitted. Then hey presto! we have a full convertible.
The wife was most impressed when I removed it. she said could I have it finished for next spring so she can use it?
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Old 08-05-2017   #34
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Re: My next project

It looks very solid although I know that photos are deceptive. How are you going to stretch the squashed areas outwards? It sounds like you have your better half well on side so maybe you'll get out to the garage pretty soon; I'm looking forward to seeing you tackle the metalwork.
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Old 08-05-2017   #35
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Re: My next project

Well, ideally I would put it on a jig and used a controlled method for pulling it. But due to its condition and the cost I will try and attach a chain to a beam that is concreted in the ground and wrap the other end around the front bumper and then push the car backwards. The front on these are rather flimsy compared with modern day car structures so I don't think it will take much to sort out the front.
The rear I will do the similar thing around the rear cross member. Failing that I will use a porta power ram to push the panels apart. Otherwise I will have to remove the rear 1/4 panel, unpick the joints between the inner wing and wheel house. I am even considering removing the rear bulkhead. this will then remove all the strength and allow me to repair each panel then weld them back together.
As you have experienced with Mitchio, when you take the sill off and the L panel you made that attaches to the rear floor, there is not much strength there so that part will repair easily.
It will be a fair bit of work - but that's the fun part
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Old 04-06-2017   #36
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Re: My next project

After pulling the front end to pull the outer panels back into line, I then removed the outer panels and gave the front inner panel a pull. Also put a great big bolt through the top shock absorber mount and pull on that as well.
this opened the gap up by about 3mm between the front wing and front edge of the door, but it wouldn't pull it any more.
Today I cut the front wings off leaving only the back edge so I can use this to keep an eye on the door gaps. Just in case things start to move. Usual rust as expected. I was going to try and save the outer arches but they were just too corroded and would end up replacing the complete lip that the outer wing welds to.
The front inner panel has been completely removed ready for a new one. I have some heavy corrosion on the upper bulkhead panel on the right side - very similar to yours Peter but not quite so bad - just a small section to cut out.
Now the front is off I might try and give it another pull on the front as the NSF A pillar will be a bit weaker now.
I also removed the panel that sits by the exhaust. It was rather bent and need to come out to straighten the rear arch. Cleaned the underseal off and 20 minutes of panel beating it is looking quite straight now.
Trouble is it is different to my L one and I'm not sure what shape the edge should be - the edge nearest the exhaust of which the additional panel is screwed to.
Is there any D owners out there who would have some good images of this panel that I could use please?
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Old 04-06-2017   #37
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Re: My next project

That's the kind of stuff I like to see.
Very sensible to try and soften the effects of any collision distortion before you really get cracking on welding etc., keep it coming.
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Old 04-06-2017   #38
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Re: My next project

Thats a project and a half Sean. Those tyres look like off roaders
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Old 04-06-2017   #39
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Re: My next project

Here you go Sean. I hope these help you. Let me know if you need any other photos.

I must get around to replacing the wiring on the oil pressure switch!
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Old 04-06-2017   #40
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Re: My next project

Quote Originally Posted by Paolo66 View Post
Thats a project and a half Sean. Those tyres look like off roaders
Snow tyres, not that I will ever need them. Snow, rain is bad enough. Think of all that road salt
I can think of someone who might use them though!
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Old 04-06-2017   #41
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Re: My next project

Quote Originally Posted by IanEmery View Post
Here you go Sean. I hope these help you. Let me know if you need any other photos.

I must get around to replacing the wiring on the oil pressure switch!
Cheers Ian,
is that panel just flat?
what about where the exhaust panel bolts on? the L one has a slight slant on the edge that tilts the bolted panel over slightly
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Old 04-06-2017   #42
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Re: My next project

Quote Originally Posted by Franko500 View Post
Cheers Ian,
is that panel just flat?
what about where the exhaust panel bolts on? the L one has a slight slant on the edge that tilts the bolted panel over slightly
Ah OK, I'll look at both my cars tomorrow and try to get some accurate pictures of that area for you.
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Old 05-06-2017   #43
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Re: My next project

Sean, OK, so I've looked at both cars which show the same detail. It's almost impossible to get a decent photo without removing the rear cross panel but I'll try to explain: the panel is formed down to an angle of about 15 dig from horizontal and the angle starts from the very outside edge of the long oval pressings which looks the same as your picture of the L. This angle then matches the angle on the exhaust shield, I can only imagine this arrangement is to get the shield on the same plain as the body panel but a couple of mm lower? Does any of that make sense?

Hope this helps you.
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Old 05-06-2017   #44
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Re: My next project

Thanks Ian,
its not the actual exhaust shield I'm interested in. Just the panel it bolts to.
Some pictures ive seen, the panel looks dead flat where the exhaust shield bolts to. Others have a slight angle on the left 20-30mm of the panel where the 2 bolt holes are.
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Old 05-06-2017   #45
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Re: My next project

Quote Originally Posted by Franko500 View Post
Thanks Ian,
its not the actual exhaust shield I'm interested in. Just the panel it bolts to.
Some pictures ive seen, the panel looks dead flat where the exhaust shield bolts to. Others have a slight angle on the left 20-30mm of the panel where the 2 bolt holes are.
Sorry, difficult to explain fully I included photos of the exhaust shield only to show the angle. I checked both of my cars in case one had the incorrect panel fitted and both cars have the angle. The angle of the fixed panel is, as close as I can make out, the same as the angle on shield. Due to the angle on the shield and fixed panel they finish up parallel but with the shield a few mm lower, measured vertically.

Have I done a better job this time?
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