"Reenie"(Now Gina)the 46 estates new thread

[dafdaffer]

is the other wheel free to turn nick?

[dafdaffer]

the brake pipe has not been crushed has it? or is the flexi dead inside?

[Nick the man with a daf....]

feels like wheel is full of rust inside the brakes or handbrake is holding on.. either way the rear brakes arent doing a lot. so its drums off time..

[dafdaffer]

i have a slide hammer which fits to the hub if your stuck

[Nick the man with a daf....]

Evening Daffers ! ! ! heres todays exciting photo filled fun with a daf !

First of all heres the belt in all its glory wearing its Ovlov part number..


as per my quicky post earlier from work I set about the brakes at morning break and rapidly turned this...




into this with the help of mr tappy bong bong stick


Mr Happy Bong Bong stick for his fans out there....


Yummy ! ! !


oh bugger.. add a cv boot to the list


Amazingly with a bit of light persuasion and a clean up around the hole I managed to get these two little people out of one side of the cylinder ..**POINTER ALERT** IF YOU ARE STRIPPING A WHEEL CYLINDER AND ONE SIDE IS FREE ALWAYS EXTRACT THROUGH THE CLEANEST SIDE AS IT SAVES PUSHING SEALS AND PISTONS THROUGH THE CORROSION ON THE WORST SIDE** ahem anyways.. with a quick polish and exam the seals were deemed fit for further service and they sat their turn


The Cylinder was far from pretty inside however, and memories of a thread recently where people cleaned up the bores with emery came to mind


but I went one better , recently we had a tool man come in and I saw on his van a little tiny Honing tool for about 14 quid


this sits in a cordless drill and when used with copious amounts of thin (thinner the better I find) it turns nasty grotty cylinders into super smooth ready to go cylinders


this cylinder recieved a few more spins before re-assembly but I forgot to photgraph that...

NS cylinder was even worse to look at


and I had to resort to Mr HBBS to get the people out of their house....

still after a damn good clean again the seals were undamaged and subtle so they were cleaned and put to one side.

the cylinder however was rank


so I started with the Honer

after a few minutes it had been transformed


I refitted the cylinders and set to cleaning up the drums
Mr Heavy Spin was brought into play along with some blue emery cloth


which in effect turns this....


nto this.... with scary ease
. . .

ok the little brake pipe that goes from the T-piece after the flexi on the axle was looking a bit cripsy so I decided he was going to leave the car and be replaced, just my luck though the pipe I had at work was the next size up so that finished my escapades for this evening...

tomorrow night brings freeing off the adjusters, and starting on the strip of the fronts and replacing the pipes where needed

thanks for checking in..... ;D

[mattsdafs]

Well done Nick,all is looking much better
Are you still on course for your dead line mot or is that now been put back a little..good luck anyway

[Nick the man with a daf....]

brakes have put the deadline back a bit

[dafdaffer]

Great work

[Nick the man with a daf....]

guess which idiot lost a wedge out of the OS brake adjuster when he was freeing it off.................

[spunkymonkey]

If you can't track one down, I'm guessing they're the same as the 66 ones? Should have one on the spare rear axle Mac dropped over to us - let me know if you need and I'll pull it apart

[dafdaffer]

bet ive got a few kicking around

[Nick the man with a daf....]

ive made one

[spunkymonkey]

Now why doesn't that surprise me?

My reputation's feeling really rather threatened right now ;D ;D ;D

[Nick the man with a daf....]

well as im gonna have to wait for my brake bits I decided to clamp off pipe to the front, pressure bled the brakes and hey presto she has a pedal...
drove her to the front fo the workshop after work and started to dig....

this little hole under the front arch

rapidly became this


now there is two pieces of metal here overlapping each other so first things first, put the inside one back


then the outside one !


finally a bit of protection till im there again


obviously need to go back and seam seal, underseal it etc, just blew a bit gf grey primer on to stop the weather gettin in for now ! ! !

[Nick the man with a daf....]

right then , as ive done the lower bit its time for the front bit.

right then, as promised my job tonight was the headlight hole on the drivers wing..

this was the state of Reenie's wing and the bit round the indicator was also ruined as it has had a donk sometime in the past...


you can see the splits around the indicator hole.

first thing mark out a circle on some galv, 205mm outer, 180mm inner diameter and cut it out (with angle grinder before anyone asks)


Cut piece needed and tacked it into place so I now had something to work to on the side piece


now be brave and cut out the curved, crusty and broken bit of wing


didnt photo much of the rest but suffice to say it took some hammering and trimming to get a patch in that hole...
now looks like this...




and with a blop of primer on for protection for now....


and showing it has some of the curves


other wing tomorrow, but thats just a bit of trailing edge repair

[Nick the man with a daf....]

evening daffers an dafferettes

this evening saw me begin to tackle the corrosion on the nearside wing of the Reenster.. On using Knot wheel we found the wing to be like this down the trailing edge...



this of course is unacceptable so out came the grinder and in a flash it became this instead



a patch was made and held up so I could scribe the line of the wing onto the rear (its not straight down there and follows the door) and after some fettling using the pan folder and a screwdriver to fold it bit by bit I had my repair section sort of to shape and ready to start welding in.






this was the panel after I had finished buzzin it on..


proper edged and folded round too, not just a patch on the front



heres some madman showing the correct atire for grinding and cutting




cool dude on the windscreen (who WILL be staying)


Works supervisor


"danger man at work"


I know what you lot are thinking... hes done it with the door off , hows it going to line up Well far better than I ever thought it would to be honest


so whats next on my agenda? not too worried about the cill rot just yet
(same both sides plus drivers sill is mostly air it would seem)

no my next task is the window apetures, because then I can put the glass back in before I break it or fall over it





this has already seem some action but to be honest I will be redoing a fair bit (nothing personal Dave, but it needs to be cut back a bit further inside mate as its still crispy in places)

drivers side isnt as bad though


very rare smiling shot

[Nick the man with a daf....]

this car really is a cow, today she bit me again...

Started off with the knot wheel on the little hole behind the pass door on the sill and it was like alice in wonderlands little door as it opened up a whole world....

Outer section chopped back to what I thought was good metal, then I realised as I fingered the steel that it was a complete skin of rust held together with underseal.


Only one thing for it I think, so out with the spot weld drill and a few minutes later I have this thing in my hand


few more spots and the entire lower section at the back is gone as far as the inner (of the three pieces)


hmm theres even rot in that as well.... that little bit at the end can be replaced


and tomorrow I take off the seatbelt mount and replace the whole section about 40mm high behind it and encompassing the rot at the side of it


then I can rebuild the middle section (spotted to the sill)
and finally put the outer back on..
this is the better side


ah well rust gone is rust gone, and every bit gone means she will last a little longer

[Nick the man with a daf....]

evening dafticians...

this evenings report starts with the sad news the nearside still isnt finished as that poxy sill took over 6 hours to reinstate back to its former glory...

I suppose you would like some pictures of this would you? well ?? would you

oh ok then ;D

This morning we were at this point,


quick blitz with the spot weld drill to remove the seat belt anchorage and the rust cut out got us to this instead

which is pretty much sound metal all around now...ok then.. lets get some metal back in there before the mice get in..
Hmm can link those two patches into one so air hacksaw at the ready and we are sorted


Cut snip fold and trim , and we have this.


Best weld that in then....

and attatch it to the heel board with spot welds as per original (as cant get in there to weld it any other way) and spot the seat belt anchor back on


Ok so thats the inside one sorted so onto the middle one now, or B-post reinforcement as I now know it to be called

hmm seem to be a pic or three short somewhere, ok trimmed it back to a neat edge and started to weld its repair section in, which is shaped with a flange along the bottom so I can spotweld up through sill to re-affix it to the outer eventually


Hmm that section where it folds looks bloomin' awful, ill trim that off


hmm GAP bridger needed


and welded in


ok so thats the middle done and secure and very strong now

right then best start thinking how im going to fit it all back inside something...
quick blitz with the pan folder saw me with this

its not perfect as to get that littel 3mm step is the work of satan in a pan folder but its close enough

oh hang on the end of that sill is holy so that best come out....


there thats better... gives me something to put the new one to.


Outer trimmed an fitted , very pleased with how it looks as well...


Jacking point spotted back on and some primer to see it all covered for now


tomorrow, bottom of trailing edge, and headlight hole on NS wing then finally onto the windows, THEN the NS will be done lol....

[Nick the man with a daf....]

Right then... where were we, last update saw me finish the sill leaving the wing tip , headlight hole, rear corners and window holes to be rectified on the NS before I could wax-oil it all up and forget about it for a while...

couldnt find my headlight rim piece I had left over so decided to start on the wing bottom instead,
This was the wing edge this morning when I got in


, well I was in no mood for taking prisoners so out came the cutting disc and before long it predictably became this instead


everything was sound underneath, and believe me im not being gentle when im looking for rust which is why some of my holes have become monstrous in size.
First thing is to cut a piece of flat the right shape to replace what ive nobbed off, and buzz it on


then simply add the return on the back edge and thats the front bit sorted


then onto the rear quarter bottom edge to replace the big hole that had already been cut in it.


quick whoosh over with the knot wheel and more is revealed

so one patch becomes two..
lets sort the big one first, cut a patch to the right size and offer it into place
put a few tacks round it to see if all is well then buzz it in




then sort out the little one left behind
hmm got no photos of that but needless to say it was done in the same way, if you are wondering why the patch has a blob of weld in the middle its teh easiest way of holding it in place, weld it to a piece of scrap so it has a handle ;D



sadly though even though I was as careful as I could be I suffered some distortion on this one still you live and learn


so thats the bottom NS done, now onto the dreaded window holes

they looked like this


and with the help of the small length of scrap side panel that came with Reenie I had some perfectly shaped repair pieces so it now looks like this


the second hole next to it (after trimming clean)


and welded up


thats a piece of aluminium in the background, sat there to stop sparks entering the cabin area as there are still front seats in ..

and then my phone battery died

although I did find this pic of one of the patches pre-weld, which shows how close a fit they are ;D



I have done a bit more, namely on the rear curve (bottom of C post where window hole sweeps round and up, it was all missing so have started to rebuild that, but with no camera it sort of takes the fun out of doing it for you guys so will leave it till im back tomorrow and photograph iwhere im at before I continue...

thanks for checking in again ! ! !

Reenies Dad

[dafdaffer]

NOw that's progress, i cant believe how fast you are getting through it.

i have not even taken mine out of the garage yet!!!

[Nick the man with a daf....]

still wish id had the coupe when I had the chance though.. but hey didnt have the space at the time sadly

[dafdaffer]

its still there

[Nick the man with a daf....]

is it now.......
well we shall see, if I get my storage anytime soon then I shall be back in touch.....
as for Reenie

my goal is to have her in paint by the end of the week

[Nick the man with a daf....]

good afternoon my fellow belters, today saw good progress on the nearside of the reenster but I still have more to do on this side, due to the amount of corrosion around the windows etc...
So where were we friday when I decided to skulk off, ah yes I had just started to address the rear corner of the apetures, this is what I had there if you remember my earlier pics.

as you can see the rear corner is totally gone inside and out, luckily I can get the majority of measurements from the OS as thats pretty much intact.
This is my template for the inner webs

so by copying this onto another piece and welding it into the corner I can get a starting line for rebuilding the corner up

add a strip to the outside of this and I have the first part of the profile on the outside sorted

now a piece to form the outside skin

and finally a curved strip so it will bevel out flat for the gap inbetween

now I tried the window in before I started on the inside as I didnt want to have to redo it all if it was a crap fit




here I marked the high spots so I could dress them a touch when the window was back out


before finally primering it and getting inside


Inside was a half hearted repair that a friend of Dave had started for him before leaving the car for 20 months and Dave having to get it back
So first things first, tidy up the edges where the sections meet and cut out the grot and weld in what we already have


start filling in the gaps using the repair bits supplied which had been chopped into small bits for some reasons


then onto the inside of the rear corner

add piece to bring it up to the first swage line

als in the picture you can see ive added a second thickness to the web on this side, and also the start of the piece that takes me up to the window line itself, formed by tapping the top 3mm over once the profile was cut to shape,
and weld it in


this still needs the groove dressing up ive run out of small discs for my air sander though.

this was all I got done today but im pleased with it as I had been dreading this bit.. so this leaves me this on the NS


and finish filling this hole in.


thanks for checking in !!!

[dafdaffer]

that is some awsome welding youth

[Nick the man with a daf....]

cheers mate, the welder is the key and mine is 40 years old and proper hardcore old school industrial mig made for car bodywork, had been using works mig but decided to get my own in and it beats the works one hands down

[Richard DAF Webmeister]

Crikey. Lot of work going on there.
Looks like you definitely have the (good) bug.

[Nick the man with a daf....]

got time off work Richard, so using it to good effect, surprising what you can achieve in a few hours without interruption

[Nick the man with a daf....]

well anyways, yesterday before it started hoofing it down I managed to add these few bits into the car.

This was the bit for behind that supporting brace in the rear,


and welded in

not sure how well that tab will line up as not got a clue what it lines up with

bit at the front (Will be getting redone as think this shows)

although its not cleaned up yet

folded this over the handle of my jack


which was intended to go here


but by then it had already started to rain quite heavily
who fancies a little update then? seeing as its been ages....

well the weather was still bad today but no water in the air so I donned a fwe layers and headed to work.

first off was cleaning up the remains of the nearside repairs and getting some primer on them. For some reason the picture of that hasnt come out???

anyways, onto the offside, after chasing the rust back to solid metal both sides I was left with a bit of a hole and needing also to remove the bottom portion of the window pillar.

First off line up the pillar and mark where it should go back


and add abackup measurement further along


then out comes mr air-saw and mr Rust leaves.
mmmm big hole


having used up all the donor section that came with the car I had no choice but to fold up some stuff of my own. This was my attempt at the window sill profile


and this bit was folded for the inside part above where those 4 little captive nuts are


First off get that metal back in the outside as at this point the whole side is incredibly flexible
Trimmed to fit....


and fitted trim

by using an air line between each weld to cool the panel I got none of the distortion I had got on the rear lower corner which was a massive relief.

next trim the bit for the inside **NOTE** there is a flange that goes around the back of the window pillar so this had to go in first, but I forgot to photograph that
.. and see if it fits


it does so with it clamped nicely in place get the welder going and buzz it in

its a fraction low at the back end but then the radius changes in that inner piece during the length of that repair so I wil have to fill it and make good
spot weld the top flange back in and we are in business, I also dressed that bit that surrounds the window pillar base tight to it and welded that in fully too.


then its onto the pillar, I had some tiny bits of the window sill profile left and these proved to be the same as the pillar so in goes a bit to make the back part of the pillar, it is straight by a rular, but it looks crooked in the pics for some reason

do the same on the front edge, give it all a clean and bosh on some primer

finally clean up the inside and primer that

and that is officially the end of the window repairs, the one bit of the car I had been dreading ;D ;D ;D ;D just OS rear lower corner an full sill to do now and the welder can be put away as she will technically be rot free
then the 5 litres of waxoil I got in the shed can go in everywhere to see if she will stay that way for a bit


(this post was made with a copy of two other posts so please ignore any strange date continuity phrases within-had forgotten my login password and the email account I had used was not being kind in recieving password information)

[Nick the man with a daf....]

time for some pictures as its been a bti too long..
the drivers side sill presented me with these little joys

At the back near the jacking point


the bit under the door



as you can see the floor is ok thankfully

picture showing how the inner cill sits in the outer cill


when I redo mine I will be making some grooves in this so water can get out rather than sitting against this membrane and rotting it out..(although the thick underseal on reenie was also filling all her water drain points on the sill, which I believe is why it failed

anyways REPAIR TIME ! ! !

start with a long strip of steel


and with the help fo Mr Edwards the pan folder create a fold


then after trimming the inner level get the buzzy stick an zap it in


then get back to mr Edwards the pan folder and have another go at making sill

first go


and finalised in profile..


now ... heres an interesting fact, the profile on these sills changes from one end ot the other.. at the door pillar end the wide bit an the step are 55mm and 25mm respectively (the lower faces) yet at the other end of the door they have increased/decreased to 62mm and 18mm so whilst still adding up to the same amount it does mean that the profile isnt simply one shape from end to end...

I will get this welded on tomorrow I hope, and I will be spot welding it up onto the repaired inner as I have no other way of joining them together unless I use sikaflex, and id rather it had metal than polyurethane lol

thanks for checking in