Astra 160iE

[JMurray]

Thanks Kev.

Think now is the time to get a 200tS. Just because the prices are about to climb now. Just look at the Superboss Mk2's now. But would say a house would be more handy thing to have though lol.

 

[JMurray]

Hopefully, the next update should be some actual progress made.

Well that was a lie!

ANOTHER four friggin years later....

Yet another unit move and continuous parts hunting.

I've caught up with other projects enough, I can haul this out and commence work on it. So far I've cleaned it out. Interior, fuel line and tank to come out next. Got a good (to not pass on it) deal on the lift.



Been flip flopping on how to repair that mess!

Strong thoughts of just replacing the whole inner sill. Outers are getting new genuine sills fitted. Well I have them in stock now, would make sense to make use of them.



No promises on how often I'll update this thread. Will try to not make it another four years!

 

[Kev_mk3]

chop chop and weld for 2025 VBOA

 

[JMurray]

I'll certainly give it a bloody good try to get something done for then .

 

[JMurray]

An update four months later!?

I can't believe it!

More investigation into the sill area happened.





Well that ain't ideal!

Been in two minds on how to fix this. I set my mind on just hacking the lot out and fit a new panel. I need access to the floor and the end of the rear chassis rail to repair them anyway. I've welded a length of box on to brace the car, now on with drilling spot welds out. I fear this will be a very time consuming task with no idea when I'll be ready to weld the outer one. I'll be doing a bit more the Christmas hols so we'll see.

 

[DavebGsi]

Good progress mate, looks like a big job you have ahead of you!

 

[Kev_mk3]

Big job broke out

 

[JMurray]

Thanks and yep it's certainly going to be a fairly big job.

Talking of which!

I was a little busy over the Xmas period. I'll let the pictures do the talking.















Yep, it was the best choice. Aim to repair the floor ready for the new panel. Rest can be worked on after that. Too tempting to cut more out. Want to treat the work as separate jobs. Unsure with the chassis leg, but that be looked at later.

 

[JerryS]

Will be satisfying when this is all done. Was really sad when I couldn't progress with my old Mk2 sxi estate. I had made a good start on a sill repair but the cross member/seat support attachment point area required some careful thought. I'm sure I could have done it given a bit more time and got another few years out of it. I'd already managed some other major repairs. Just ran out of time. Mechanics were all still fine of course.
Hope you can stick with it.

 

[JMurray]

I can very much sympathise with you said.

It's not an easy decision to call time on a project. Specially when outside influences come into play.

This project will be chipped away at. I've not given myself a deadline at the moment. As I wanna enjoy the process. Could easily grow to hate working on it quite quickly . That's mostly down to the fact I've done other cars and they've been a slog to do.

 

[JMurray]

The progress just keeps coming!



New panel prepped. Perfect time to drown it in my fave red oxide primer. Bonda rust primer if anyone is interested.

Finally used some of that sill cut I got years ago. Needed this on first for setting the new inner on to. A play with my welder setting and was getting much nicer welds. Using a bit of copper behind helped with heat management.





Then for the moment I've been waiting for years.



Still to finish welding it in, but it already looks a million times better!





Such a relief to see this area with fresh metal. Good start point to build to and from. I'll dress down the welds later on.

 

[Kev_mk3]

Good stuff keep it going

 

[JMurray]

Thanks Kev .

 

[DavebGsi]

great progress mate, gives me good memories of doing mine! It so satifying!

 

[JMurray]

Cheers Dave .

It really is nice to see that lump of rot gone. That was the section I had been worried about for years.

As mentioned on your thread, I've been reading up on what you did with yours. As mine is rusty in nearly the same places. So I'm getting a good ideas on how to repair it.

 

[JMurray]

Typical.

I want to crack on with this car, yet I find other things to do!




Back at it now.

Soooo. That's the new inner sill connected to the car. I can remove that brace as it was getting in my friggin road!



Still to finish the floor to inner welding. Like a an hour will see that done. Seat mount rail thingy to go back in.



This is what it'll stay like for a while. I intend to beg/borrow/buy a rollover jig for doing the rear chassis leg repairs without the ramp being in my road, then treat and paint the whole inner and then put a new outer sill on.

Next major job will be the fuel filler area. New sections have been bought.

 

[rickisgrate]

Typical.

I want to crack on with this car, yet I find other things to do!

View attachment 27906


Back at it now.

Soooo. That's the new inner sill connected to the car. I can remove that brace as it was getting in my friggin road!

View attachment 27907

Still to finish the floor to inner welding. Like a an hour will see that done. Seat mount rail thingy to go back in.

View attachment 27908

This is what it'll stay like for a while. I intend to beg/borrow/buy a rollover jig for doing the rear chassis leg repairs without the ramp being in my road, then treat and paint the whole inner and then put a new outer sill on.

Next major job will be the fuel filler area. New sections have been bought.

I need to get my fuel filler bit done as well

 

[JMurray]

Just about standard on all MK3's that area needs welded.

I've bought the same inner panel as Dave had for his resto. Got an outer section too. I have noticed an issue with the inner which is fixable. Not the suppliers fault. Just something to be aware about. It's for an Estate, the bumper mount flange thingy bit is a different profile. I'll get pics to explain it better.

Got both from Car panels 4 you. Had to wait on the inner panel as that had to be ordered in. About two weeks in the end. Both have arrived today.

 

[rickisgrate]

I'll have a wee gander and get one ordered up

 

[JMurray]

Here is the differences in the two.


That's hatch/saloon.

This is the Estate one.



I'm chopping these apart anyway. So it doesn't bother me with the difference.