[body_work] Floor...

[DamirGTI 323]

 

 

... after a poke :

 

 

...

 

Wtf should i do with this the s*it of an floor ?!?!?!?

 

I guess you'll all say - scrap the car (well that does make sense ..) but lets say that i'm keen with welding and have loads of spare time - how hard is to fix this up ? from 1 to 10 ?

 

LH side seems to be good bar the few areas ... however this the RH one is .. well you can see for yourself , in 100% s*it state ..

 

 

Damir

[bren_1.3 1]

you pull that car from the bottom of the ocean???

 

its not difficult to sort out, (in comparison to say the ford escorts) a lot of it is just cutting back/out the rust and welding in fresh stuff. maybe weld in a couple of steel bars to replace the old seat rails while your at it?

[cybernck 400 1 Cars]

i told you to stop with those drives on the beach!

 

if i were in your shoes, i'd find a good one in a scrap yard and cut out the parts i need.

 

and i agree with what bren's said about strengthening and seat mounts.

[Alfie 6]

you pull that car from the bottom of the ocean???

 

its not difficult to sort out, (in comparison to say the ford escorts) a lot of it is just cutting back/out the rust and welding in fresh stuff. maybe weld in a couple of steel bars to replace the old seat rails while your at it?

I would see if replacement floor panels are still available. The difficulty is replicating the varying shape AND strenght of the original floor. New panels= no problem if you can mig well. IMHO.

[DamirGTI 323]

Yes it does look like it's from the ocean .. from what i've seen it's been involved in some kind of crash on the RH side and repaired afterwards

 

Well the seat rail is still reusable (with a little bit of welding) and the main bottom rail is also good ... it's just this top floor layer which is so damn rusty

 

 

Damir

Edited November 6, 2008 by DamirGTI

[bren_1.3 1]

I would see if replacement floor panels are still available. The difficulty is replicating the varying shape AND strenght of the original floor. New panels= no problem if you can mig well. IMHO.

 

i was going to say that.. but (and ive never had a real good look) i think the floor section is quite a substancial panel in a 205....and at peugeot prices probably astronomical.

 

if you wanted the old floor shape back then maybe buying a new panel would be appropriate, and cutting out/ welding in the sections needed. however if damir wasnt so bothered about that, then sheet steel would do the job?

[DamirGTI 323]

i told you to stop with those drives on the beach!

 

if i were in your shoes, i'd find a good one in a scrap yard and cut out the parts i need.

 

and i agree with what bren's said about strengthening and seat mounts.

 

 

Could make an aquarium out of this car easily .. anyway i have another one but i didn't finish that one yet , this red "aquarium" one has full MOT for 10 months and all the suspension/mechanical stuff are repaired/replaced so they're in mint state .. it's just this damn floor ...

 

I will see if i can find donor with good floor panel cos the new ones aren't available no more .. or , if nothing i'll buy an plate of steel and fix this up bit by bit ..

 

Should i weld a steel bar between the A-pillar and B-pillar before cutting out this section of the floor ? you know like when changing the sills ?!

 

Damir

Edited November 6, 2008 by DamirGTI

[DamirGTI 323]

.. anyway i have another one but i didn't finish that one yet

 

.. this one :

 

.. and it's a good un , but it needs full respray , MOT and some other bits and bobs to sort out .. however i don't have money for all this now ..

 

 

.. this one is the "aquarium" car above :

 

 

Damir

 

EDIT : Ok. i still need a bit of info regarding this :

1 Should i weld a steel bar between the A-pillar and B-pillar before cutting out this section of the floor ?

2 Which thickness of the sheet steel should i buy for repairing this ? 0.80mm or thicker/thinner ?

 

Thanks !

Edited November 6, 2008 by DamirGTI

[Tom Fenton 1,519]

Christ on a bike, that is a mess, never EVER seen a 205 rot like that before! Has it been stored in the sea?!?!

 

Anyway, its certainly fixable if you are brave, as others say it will make your life much easier to cut sections from a scrap car, but of you can't find one, then flat sheet would do the trick TBH.

[DamirGTI 323]

I'll see what can i do

 

Can you answer my questions above please ?

 

Damir

 

(it's an early 87year car , so me thinks that this one isn't galvanized ..)

[Tom Fenton 1,519]

I wouldn't bother welding a bar between pillars, just keep the car still and don't move it after you cut out the crap.

 

As for thickness, 0.8 is a bit thin IMO, 1.2 or 1.6 would be better.

[DamirGTI 323]

Thanks !

 

Damir

[de Noir 0]

OMG Damir! I didn't know it's that bad!

 

I would break the car, keep what's in order and bin this unworthy shell, but that's me.

In my opinion, saving it isn't worth the effort. (I told you so!)

[DamirGTI 323]

I know , to be honest didn't realize myself that is this bad .. but i really don't have a choice now either to fix it or scrap it , but if i scrap it then what ?! , at least i can do is - try ... the worst thing that can happened is that it could make me sooo pissed off if i suck with something , in that case i'll pull him out of the garage and ignite the bastard ASAP

 

Damir

 

(i always had bad luck with these cars an 100% jinx ..)

Edited November 7, 2008 by DamirGTI

[DamirGTI 323]

Chopped off the rubbish bits today (well almost all of them .. the worst bits anyway) :

 

Cleaned up the main chassis rail , which seems to be in reasonable state as well as the floor stiffener :

 

Fully seam welded inner and outer sill together from the bottom and added flat steel bar on the inner sill which will be support for welding floor panel on that side :

 

 

....

 

Damir

[matty_gti 20]

Well done damir, I think over here that car would of gone to the car park in the sky....

[DamirGTI 323]

This one will go to the crunchyard , in one direction , and i'll press the crunch machine button personally ... but when the MOT expires and when i fully prepare myself my other car .. until then i'll try to stitch this up and use the bugger just for local transport for say 6 months ..

 

Damir

[DamirGTI 323]

Started to make floor mockups from cardboard today ...

 

Cutting cardboard bits (decided to make mockups from two cardboard pieces ... however later on i'll try to cut the panel from sheet steel in one piece ..) :

 

 

Final mockup shape (few bits are missing but i'll add them later on when i start cutting the panel from the sheet steel ..) :

 

 

 

.... and now the hardest bit - cutting this shape from steel as accurate as possible , bending , modeling etc. (i really like welding bit so thats not a problem , but i HATE this cutting - bending - shaping - modeling stuff )

 

Light an candle for me !

 

Damir

Edited November 8, 2008 by DamirGTI

[cybernck 400 1 Cars]

i'd leave it like that mate, just "weld" it with some sellotape and spray it red .

[DamirGTI 323]

was expecting this comment ... well , don't be shy , feel free to drop by if you know how to weld cardboard i'll prepare the "rakija" and all the extras for refreshment after the work

 

Me thinks that i'll be fine with steel although this 1.00mm one is a bit hard for bending i'll try with one step thinner 0.80mm sheet , that one must be easier for modeling/bending but still strong enough ..

 

Damir

[SurGie 54]

Yeh If you put the aluminium welder set to the lowest setting you can

weld cardboard perfectly to the 205's chassis / Perfek Rodder's

[DamirGTI 323]

Decided to wait my mate (he's a body man ..) who kindly offered to drive around 140 miles up to my place (respects ! ) just to take a look at this crap floor as well as the complete shell and give me a bit of advice what will be the best approach in order to sort this out ..

 

While im waiting , i decided to inspect some more around the shell and i've found some more crap bits

 

Crappy/loosen joints around B pillar , inner sill and rear crossmember :

 

Hole from nowhere ?! :

 

... fixed :

 

 

Bottom B pillar to sill joint (not cracked but covered with lots of ugly looking welds ..) :

 

... fixed (ground down to the base and re-welded ..) :

 

Now this is interesting :

... can't find not a single rust spot on the front panel nor the inner wings ..

 

Damir

Edited November 12, 2008 by DamirGTI

[welshpug 1,620]

note the part number sticker on the fan cowling, I would say that had been replaced at some point, maybe explains the lack of rust, the metal isn't as old as the car

[DamirGTI 323]

I guess so as well cos it's 100 % rust free at the front ..

 

Damir

[SurGie 54]

That has def had a new front end on it, are the inner wings all straight ?