It's always worse than it looks

[PCOATES505]

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!!

 

[PCOATES505]

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.


Passnegr side sub-frame rear jack point


Passenger side floor

 

[PCOATES505]

Some repairs needed

I started work repairing the sill (inner and outer)


I cut out the rear section

made up a repair section

and welded it in


Then cut out the front section
and repaired the inner sill

 

[PCOATES505]

Front floor

The passenger side front floor was a bit thin

So I cut it out and made up a repair section


and welded it in

 

[PCOATES505]

Next

came the sub-frame

 

[PCOATES505]

Then came

the rest of the sill

 

[PCOATES505]

Driver side

After removing the drivers side sill cover I discovered it was worse than the passenger side.


so the cutting and patching continued.




rear jack point

 

[PCOATES505]

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..



The replacment doors were also stripped back and prepared

 

[PCOATES505]

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.




The assembly took ages

 

[PCOATES505]

The next phase

After all the body work was re-assembled


The front and rear sreens were re-fitted


Next came the task of getting the car roadworthy.

 

[iron oxide]

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...

 

[gerrypro]

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??

 

[Binky]

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

 

[catshamlet]

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.
View attachment 9633 View attachment 9634 View attachment 9635

View attachment 9636 View attachment 9637 View attachment 9638

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. :wink2:



Mike.

 

[PCOATES505]

Rofl

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

 

[PCOATES505]

justifiably

Very impressive!

I was proud of my 504 buttress panel repair,

I thought you did a bloody good job too!!
cheers Pete

 

[PCOATES505]

Easy

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


Flanging tool

 

[gerrypro]

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

View attachment 9704
Flanging tool
View attachment 9705

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

 

[luthier]

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

 

[J'aime la vie]

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