It's always worse than it looks
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  1. #1
    Fellow Frogger! PCOATES505's Avatar
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    Default It's always worse than it looks

    Back in the days before the crash of 2010 I had a thread about the refurbishment of my 1963 Peugeot 403B, this is a re-creation
    I bought a 403 that had been a daily driver, but was taken off the road because of a smoky engine, and that's a story worthy of another thread.
    The interior was pretty good, but it had very rusty doors. It didn't appear to have any other rust. Yeah right!!
    It's always worse than it looks-100_0301.jpg

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    It's always worse than it looks-100_0302.jpg
    Last edited by PCOATES505; 7th November 2010 at 07:25 PM.

    I am gunna get another 403 on the road........one day

  2. #2
    Fellow Frogger! PCOATES505's Avatar
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    Default It begins

    I had some good doors, so I decided to fit them and give the car a paint job.
    First step was to remove the sill covers, thats when I found this.
    It's always worse than it looks-100_0313.jpg It's always worse than it looks-100_0314.jpg

    Passnegr side sub-frame rear jack point
    It's always worse than it looks-100_0312.jpg It's always worse than it looks-100_0327.jpg

    Passenger side floor
    It's always worse than it looks-100_0328.jpg
    Last edited by PCOATES505; 7th November 2010 at 07:28 PM.

    I am gunna get another 403 on the road........one day

  3. #3
    Fellow Frogger! PCOATES505's Avatar
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    Default Some repairs needed

    I started work repairing the sill (inner and outer)
    It's always worse than it looks-100_0316.jpg

    I cut out the rear section
    It's always worse than it looks-100_0317.jpg
    made up a repair section
    It's always worse than it looks-100_0322.jpg
    and welded it in
    It's always worse than it looks-100_0325.jpg

    Then cut out the front section
    and repaired the inner sill


    It's always worse than it looks-100_0330.jpg

    I am gunna get another 403 on the road........one day

  4. #4
    Fellow Frogger! PCOATES505's Avatar
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    Default Front floor

    The passenger side front floor was a bit thin
    It's always worse than it looks-100_0331.jpg
    So I cut it out and made up a repair section

    It's always worse than it looks-100_0332.jpg
    and welded it in

    It's always worse than it looks-100_0339.jpg
    It's always worse than it looks-100_0338.jpg
    It's always worse than it looks-100_0350.jpg
    Last edited by PCOATES505; 7th November 2010 at 04:44 PM.

    I am gunna get another 403 on the road........one day

  5. #5
    Fellow Frogger! PCOATES505's Avatar
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    Default Next

    came the sub-frame
    It's always worse than it looks-100_0340.jpg It's always worse than it looks-100_0343.jpg

    It's always worse than it looks-100_0344.jpg It's always worse than it looks-100_0345.jpg

    It's always worse than it looks-100_0346.jpg

    I am gunna get another 403 on the road........one day

  6. #6
    Fellow Frogger! PCOATES505's Avatar
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    Default Then came

    the rest of the sill
    It's always worse than it looks-100_0348.jpg

    I am gunna get another 403 on the road........one day

  7. #7
    Fellow Frogger! PCOATES505's Avatar
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    Default Driver side

    After removing the drivers side sill cover I discovered it was worse than the passenger side.
    It's always worse than it looks-100_0351.jpg It's always worse than it looks-100_0352.jpg It's always worse than it looks-100_0353.jpg

    so the cutting and patching continued.

    It's always worse than it looks-100_0359.jpg It's always worse than it looks-100_0360.jpg It's always worse than it looks-100_0361.jpg


    rear jack point
    It's always worse than it looks-100_0354.jpg It's always worse than it looks-100_0355.jpg

    I am gunna get another 403 on the road........one day

  8. #8
    Fellow Frogger! PCOATES505's Avatar
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    Default After the rust

    With all the rust work done, the car was off to the painters where it was stripped of all trim , glass, door handles and lights and scaped back to the original undercoat..
    It's always worse than it looks-100_0439.jpg It's always worse than it looks-100_0438.jpg


    The replacment doors were also stripped back and prepared
    It's always worse than it looks-100_0440.jpg

    I am gunna get another 403 on the road........one day

  9. #9
    Fellow Frogger! PCOATES505's Avatar
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    Default Some assembly required

    After the car came back from the painters, with it's fresh coat of 2 pack, the job of putting it all back together began. New window tracks and door seals all round.
    It's always worse than it looks-100_0507.jpg It's always worse than it looks-100_0555.jpg It's always worse than it looks-100_0554.jpg

    It's always worse than it looks-100_0550.jpg It's always worse than it looks-100_0551.jpg It's always worse than it looks-100_0552.jpg

    The assembly took ages

    I am gunna get another 403 on the road........one day

  10. #10
    Fellow Frogger! PCOATES505's Avatar
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    Default The next phase

    After all the body work was re-assembled
    It's always worse than it looks-100_0642.jpg It's always worse than it looks-100_0643.jpg

    The front and rear sreens were re-fitted
    It's always worse than it looks-100_0670.jpg

    Next came the task of getting the car roadworthy.

    I am gunna get another 403 on the road........one day

  11. #11
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    Default

    Fantastic pics and very inspirational! Just in the nick of time as I'm about to start on a major push to get my Dee painted/derusted etc...

  12. #12
    1000+ Posts gerrypro's Avatar
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    Default

    Quote Originally Posted by iron oxide View Post
    Fantastic pics and very inspirational! Just in the nick of time as I'm about to start on a major push to get my Dee painted/derusted etc...
    DS Chassis...Hmmmmmm...yep that is a good place to test your rust repairing skills!!
    Cheers Gerry

    PS ---Great work on the 403. They look like very well made repair panels. Care to provide some how to notes??

  13. #13
    Fellow Frogger! Binky's Avatar
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    Very impressive!

    I was proud of my 504 buttress panel repair, but your work leaves mine for dead!

    ...I guess we've all got to start somewhere though...

    I'm just glad to see another 403 saved!

    Congrats

  14. #14
    1000+ Posts catshamlet's Avatar
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    Default

    Quote Originally Posted by PCOATES505 View Post
    After the car came back from the painters, with it's fresh coat of 2 pack, the job of putting it all back together began. New window tracks and door seals all round.
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    The assembly took ages
    Now I know why you folk call 'em headlamp buckets! (pics 4 + 6)

    Bet you don't get that thing finished by Christmas.



    Mike.
    Started out with nothing, still got most of it left.

  15. #15
    Fellow Frogger! PCOATES505's Avatar
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    Default Rofl

    I thought the plastic wouldn't rust, but it was too big for the hole.
    cheers Pete

    I am gunna get another 403 on the road........one day

  16. #16
    Fellow Frogger! PCOATES505's Avatar
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    Default justifiably

    Quote Originally Posted by Binky View Post
    Very impressive!

    I was proud of my 504 buttress panel repair,
    I thought you did a bloody good job too!!
    cheers Pete

    I am gunna get another 403 on the road........one day

  17. #17
    Fellow Frogger! PCOATES505's Avatar
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    Default Easy

    Quote Originally Posted by gerrypro View Post
    DS Chassis...Hmmmmmm...yep that is a good place to test your rust repairing skills!!
    Cheers Gerry

    PS ---Great work on the 403. They look like very well made repair panels. Care to provide some how to notes??
    When you have the tools, I had the use of a friends workshop with a guillotine and folder.
    This was hand bent around a piece of pipe, then the edge bent in the folder. I later went along the other edge with a flanging tool

    It's always worse than it looks-100_0336.jpg
    Flanging tool
    It's always worse than it looks-100_0326.jpg
    Last edited by PCOATES505; 9th November 2010 at 10:47 PM.

    I am gunna get another 403 on the road........one day

  18. #18
    1000+ Posts gerrypro's Avatar
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    Default

    Quote Originally Posted by PCOATES505 View Post
    When you have the tools, I had the use of a friends workshop with a guillotine and folder.
    This was hand bent around a piece of pipe, then the edge bent in the folder. I later went along the other edge with a flanging tool

    Click image for larger version. 

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    Flanging tool
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    Availability of tools is a significant factor. I make do with clamps and bars for use with an I beam edge to bend metal with planishing hammer and dolly. Aviation snips and metal blades in a jig saw for cutting. I have been able to make some fairly complex small panelsm but these tools introduce distortion when making long straight pieces. A Guillotine and a folder would be heaven. I once saw a diagram on how to make a folder out of cheap steel sections available from any local steel merchant. Wish I could find it now!! Keep up the good work.
    Cheers Gerry

  19. #19
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    Default

    Great work Pete, what kind of welder are you using? TIG?

  20. #20
    Fellow Frogger!
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    Pete good to see this thread back and the images. It like getting a whole comic at once.. instead of the weekly installments.

  21. #21
    Fellow Frogger! PCOATES505's Avatar
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    Default If only

    Quote Originally Posted by luthier View Post
    Great work Pete, what kind of welder are you using? TIG?
    All the work was done with a MIG, I don't think my eyesight is good enough to use a TIG.
    Sometimes when I am welding I do the most perfect looking weld.................right next to the join that I was welding. Wish I had young eyes again.
    cheers Pete

    I am gunna get another 403 on the road........one day

  22. #22
    Fellow Frogger! PCOATES505's Avatar
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    Default Should I

    continue the engine rebuild here or start a new thread??

    cheers Pete

    I am gunna get another 403 on the road........one day

  23. #23
    1000+ Posts gerrypro's Avatar
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    Quote Originally Posted by PCOATES505 View Post
    continue the engine rebuild here or start a new thread??

    cheers Pete
    Put it in here so that it is easy to find and that we all know to which car it relates.
    Cheers Gerry

    PS I found a set of plans for a Sheet Metal Bending Brake. Some people may be interested.
    http://www.millerwelds.com/
    Click Do it yourself tab-----welding projects------scroll to bending brake and click!!!!!!
    Let me know if anyone makes one!!!!
    Last edited by gerrypro; 12th November 2010 at 10:19 AM.

  24. #24
    Fellow Frogger! sideways_505's Avatar
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    Default

    Very nice work!

    403s can rust all right! Mine came with $4200 worth of receipts for work done just to the sills! Then there's all the rust in the doors and boot and engine bay and.......... That I have to fix.

    I wish I had the tools you do, I'm slowly building the collection, haven't even got a MIG yet though.

    Thanks for sharing.

    Hayden

  25. #25
    Fellow Frogger! PCOATES505's Avatar
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    Default Smokey motor

    [QUOTE=PCOATES505;903585]Back in the days before the crash of 2010 I had a thread about the refurbishment of my 1963 Peugeot 403B, this is a re-creation
    I bought a 403 that had been a daily driver, but was taken off the road because of a smokey engine, and that's a story worthy of another thread. QUOTE]

    After getting the body work finished I set about getting the car roadworthy. The car had been serviced and repaired by a prominent Melbourne service centre and had buckets of money spent on it in its 5 years as a daily driver, until it was taken off the road because it was blowing so much smoke. The previous owner told the mechanics about the smokey motor, so the motor was removed and repaired, which consisted of one s/hand piston, new rings, new big end bearings. After re-fitting the motor continued to blow smoke and after 1500 miles the owner gave up and took the car off the road. It sat in the street for 2 years, until I rescued it.

    Going through the mechanicals to get it roadworthy, I was appalled at the standard of work that had been done. The brakes on the car had been reconditioned twice, so all should have been well.
    I re-rubbered all the wheel cylinders and replaced the master cylinder, but found this in the back brakes
    It's always worse than it looks-100_0370.jpg
    A staple stuck in the handbrake, which had worn out the front shoe, this was done on both sides.

    The front wheel bearings were done up so tight that when the hub was turned you could feel the balls trying to rotate, they felt square!!. Steering rack boots were shot, tie rod ends needed repair and the king pins needed new thrust washers. The owner had complained about knocks in the front end. The front shockers were so stuffed I couldn't rebuild them, so they went in the bin and I rebuilt some replacements.
    Next is was time to deal with the smokey motor

    I am gunna get another 403 on the road........one day

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