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EXTERIORS & BODY REPAIRS Bring your beloved back to its former glory - or just polish the chrome some more!

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  #16  
Old 28th April 2008, 06:14 AM
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Default Re: The Chronicles Of Mercules - Body Repairs

I am sitting here at 6.30am shaking my head with amazement.

This impressive Mercules....

Can't wait for the rest of the story
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  #17  
Old 28th April 2008, 08:05 AM
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Default Re: The Chronicles Of Mercules - Body Repairs

HUGE EFFORT CAM!!!! well done mate
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  #18  
Old 28th April 2008, 12:29 PM
John S John S is offline
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Mercules, what a fantastic effort! I can hardly believe that there was so much rust in that / those positions. Soon after I bought the car (11 or 12 years ago) I had Axel at Vehicle Color Design cut out some rust from the firewall and under the mudguard at the rear, and I thought that the rest of the body was OK!! How wrong I was!!

Thank goodness you have the car now, as I am certain that the amount and quality of the work you are detailing would be too much for the other 99% of us!
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  #19  
Old 28th April 2008, 10:39 PM
Mercules Mercules is offline
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Default Re: The Chronicles Of Mercules - Body Repairs

Here is a little diagram I made of the fusebox layout... not sure how it translates to other models & build dates but hey, it could save you a lot of crying if you mess up the wiring!!! (DIAGRAM IS LOOKING FROM UNDERNEATH AT THE WIRES & SCREWS THEMSELVES)



(first colour deontes wire colour, second & third colours denote tracers)
  1. red/blue
  2. black/red + black + black 5 wire
  3. black/red x 2 + black/yellow/green
  4. black/green + black/purple + black yellow
  5. black/purple + black/red + black
  6. red x 2 + red/white
  7. red/black x 2 + black/red
  8. grey
  9. grey/white
  10. black (sheathed)
  11. red + red/yellow + red/grey + red/white + black
  12. blac/green + black/pink/green
  13. grey/red x 3
  14. grey/black x 2
  15. grey/green/yellow
  16. white/blue + white
  17. yellow
  18. red/yellow + red
  19. white
  20. yellow
  21. red/blue
  22. white/black
  23. yellow/black
  24. red/white + red/black
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Last edited by Mercules; 28th April 2008 at 10:56 PM.
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  #20  
Old 28th April 2008, 10:45 PM
Mercules Mercules is offline
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Default Re: The Chronicles Of Mercules - Body Repairs

Thanks for the comments guys - very encouraging!

Don't fret just yet John - there is some more to come! The passenger side needs a little tidy-up then its into the boot floors.

NOTE: High definition rust porn has been updated on page 1
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Last edited by Mercules; 28th April 2008 at 11:08 PM.
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  #21  
Old 1st May 2008, 09:14 AM
John S John S is offline
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Default Re: The Chronicles Of Mercules - Body Repairs

Cam, I have been trying to think of how rust could occur in that particular location and it finally came to me that the front right sunroof drain that runs down the pillar may stop short in that spot so thatís where rain is directed instead of to the ground.

I was talking to Ben de Boer last night (Wed 30th) and he said that there are a few possibilities to check, the rubber drain pipe from the sunroof can crack due to age and the water drips into that area, the metal pipe from the sun roof can rust through where the rubber hose connects so the water leaks there, or the 'tray or frame' of the sunroof itself can rust at the edge and the water then drips into that front right area again. Ben mentioned that the headlining is easy to drop down a little at the sunroof opening and you can get a good look at the tray and see if it is rusted. I hope these comments are of some use as I would hate for rust to form again.
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  #22  
Old 1st May 2008, 02:37 PM
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Default Re: The Chronicles Of Mercules - Body Repairs

With the firewall rust, I suspect it starts at the seam and works its way up/down/across, possibly also at the bonnet cable entry point too. This could be due to an accumulation of dirt/leaves which might be mildly acidic when water enters the equation (which will pool in this area depending on how the car is parked on a slope from left to right, eg. in the street. This could also be responsible for RHS doors rusting out, as the drain holes are on the outer edge! This could also explain why the passenger side firewall is more often rusted out too).

Perhaps the contact adhesive used to secure the deadening material in the engine bay has the ability to hold some moisture too. Once the water is able to enter the cabin, I think this is when it rusts out the lower portion of the firewall where the moisture is retained in the foam. The floor pan is next in line!

Tim
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  #23  
Old 1st May 2008, 02:59 PM
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Default Re: The Chronicles Of Mercules - Body Repairs

I agree with everything TJ450 says based on my obs.

The rubber boot around the 6.9 suspension cable where it goes through the firewall on the LHS is a site of rust.

For many (most?) W116s nowadays, it's like Mercules said - the one without rust is the one that's been fixed.
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  #24  
Old 4th May 2008, 08:15 PM
Mercules Mercules is offline
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I am absolutely stuffed after today...

I cleaned up the rest of the rust chopping next to the fusebox then made some cardboard templates






I then spent about 2 hours looking for some sheet metal - everything I found was either aluminium or galvanised - the guy in the unit next door had a small sheet so I chopped and hacked then welded and grinded my way into oblivion.





If you think it looks nasty then you are very observant... as a welder I make an amazing country music singer! As bird-sh#tty as it looks, it is very very strong and once smoothed and painted it will be fully sick mate. My brother spent the day cleaning up then cutting out the wheel wells - the previous rust repair on the O/S was holding strong but the steel it was welded to was hole-ier than the Pope. Has all been cut out and once the other side is done we can remake the floors.

My brother couldn't help himself... there were some 19" Volk Racing wheels off a GTR Skyline just sitting around so whe sat them on the hubs...phat!






More next weekend!
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  #25  
Old 5th May 2008, 06:27 PM
John S John S is offline
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What a great job you are doing on the body Cam - in the distant future I hope that the dints from the hailstorm pop out easily when you get around to the cosmetics.
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  #26  
Old 5th May 2008, 10:30 PM
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Default Re: The Chronicles Of Mercules - Body Repairs

Hi JohnS, it's one of those jobs where you couldn't blame anyone from holding their arms up in the air and just chucking it in. Mercules has already shown to many of us what he is capable of doing and the speedy manner in which he can work.

As far as the hail damage is concerned, I have offered to him the boot lid that you passed onto me a little while ago. That may help a little. Regards Styria
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  #27  
Old 5th May 2008, 11:09 PM
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Default Re: The Chronicles Of Mercules - Body Repairs

Nice wheels mate, definately phat!

Great work on the rust repairs, you're crankin through this.
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  #28  
Old 7th May 2008, 01:53 PM
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Excellent news today - my brother invited his mate (a sparypainter) over to have a look at it for me and give me some opinions on the windscreen rust repair and the work I had done so far... he also took a paint smaple and is mixing up a litre of paint for me so I can re-spray the rust repairs and under the bonnet!

Here was me thinking I was just going to put on a coat of matt black and pull it apart later for proper painting!!!

Looks like the front end re-assembly will commence on Saturday afternoon and hopefully by Sunday it will be driveable and the rear rust well on its way to being eradicated!!!

Can't wait for the weekend now - driving my Mrs' Corolla is drving me bonkers



Cam
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  #29  
Old 10th May 2008, 06:23 PM
Mercules Mercules is offline
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Big progress made today... this is how we started out.



I had a dig around the passenger side and found some rust starting!



Sorted that out ans prepped it up - hit it with some primer first



Voila - fresh coat and no rust to be seen!





Passenger side back together



Got the fusebox in and the harness thru... now to wire up the fuse blocks!




I am stuffed after today... excuse me while i collapse on the floor
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  #30  
Old 10th May 2008, 07:14 PM
John S John S is offline
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Default Re: The Chronicles Of Mercules - Body Repairs

I continue to be impressed Mercules, I'm really looking forward to seeing it at a 116 get together (If I can come in a 210).
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