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205 body shell repairs
nick205 - 16/12/13 at 03:27 PM

Now busy working on my new 205 body shell to get it ready for a rebuild. Starting from the top it has the common crack from the B pillar along the top of the rear window (not unsurprising as it's been used for racing). There's also some rust evident.

How would you best tackle repairing this to a good standard?

Minicooper - 16/12/13 at 03:51 PM

I would use a ratchet strap and pull the crack together, this would close up the tack weld that looks like it has broken and re weld. It should close up fairly easily

David

nick205 - 16/12/13 at 03:55 PM

Hi David,

I did wonder about pulling it back together somehow. My worry is the roof is so flexible that pulling it with a ratchet strap could easily buckle it, which would be a nightmare.

Minicooper - 16/12/13 at 04:05 PM

Hello Nick,
I think it would come in fairly easily. If that doesn't look like it would work, is there anything on the inside like an edge to the roof you can get hold off and pull down?

David

nick205 - 16/12/13 at 04:11 PM

Possibly...I might get away with making up some wood packing and using a big clamp to squeeze it together.

Might have a fiddle tonight and see how easily it moves.

The other side is the same, as are the bottom of B pillars to the sills. If I wasn't so worried about buckling the roof, a big ratchet strap round the whole car might well pull everything together at the same time

T66 - 16/12/13 at 05:01 PM

Get a bit of hardwood laid along the top of the window frame, and a piece of 4x2 on the top of your trolley jack, and carefully put the cars weight on the crack. Tack it up then drop it off the jack.

nick205 - 16/12/13 at 05:14 PM

Good call, that might work as well.

loggyboy - 16/12/13 at 08:05 PM

Why bother pulling it back at all? Just reweld the seam as is. If you reweld it under strain its more likely to crack again if you force it closed.

Ps, thanks for dropping the socket back, glad the car feels better!

Mark Allanson - 16/12/13 at 09:53 PM

It may have something to do with all the spots having been drilled out of the rear quarter glass seam!

sdh2903 - 16/12/13 at 10:25 PM

Weld as is, better penetration with a slight gap.

nick205 - 16/12/13 at 10:49 PM

quote:
Originally posted by Mark Allanson
It may have something to do with all the spots having been drilled out of the rear quarter glass seam!


Fair point although they have been pretty careful to avoid them. I'm planning to weld all the holes up anyway using a block of copper behind as a heat sink.

nick205 - 16/12/13 at 10:51 PM

quote:
Originally posted by loggyboy
Why bother pulling it back at all? Just reweld the seam as is. If you reweld it under strain its more likely to crack again if you force it closed.

Ps, thanks for dropping the socket back, glad the car feels better!


Fair comment again, it's a concern putting such small welds under tension.

Cheers again for the socket, car feels"alive"again!