Project Scala.

[Reverend Frog]

You've got to hand it to both Mark and the owner as well - I'd have been tempted to call the scrapper's van if my car was in that state

[decon]

Excellent work on the scala.

[markh]

More trouble uncovered. I've never seen one badly rotted here before.


Its a real awkward area to get to with the welder, so it may end up just being bridged with fibreglass.
This is the next area to be tackled. Due to its position under the speaker shelf its a real ballache to weld.

I cut out the rotten piece.

Due to the awkward shape of the panel, i made the repair piece up in two sections to make life easier.

I also welded the repair from the underside and painted the welds with seam sealer.

Then give its first skim of filler, its gonna need more to get it looking ok.

I also had time to rub down the rear panel. skim it with filler again, rub it down once more and finally paint it with rust proofing zinc primer.

Still tonnes to do but im beginning to think theres light at the end of a very rusty tunnel !!

[Reverend Frog]

I cannot comprehend how someone allowed their car to get into this state.....must have been exclusively used on gritted roads!

My first Rocco was a bit shabby on it and when I saw it again before scrappage its arch had gone there as well.

[Ryan]

Or parked in the sea

[markh]

Repaired the rear edge of the drivers side arch.

Including the lower quarter panel.

Dressed the welds and then skimmed the patch with filler which still needs to be rubbed down.

I cut out the last of the rot from the front edge of the arch and will weld it up tomorrow.

[mattg34]

Ha Ha, i didn't realise you had posted it on here, its famous!! I've gotta say Mark looking at it on here really makes me aware of all the hard graft you've put in bud! That really is some skill putting all that rust to bed. I can't belive it was that bad and ,like i said to you how the hell the mot guys missed it i don't know!! Still no joy there, they don't want to know, saying it was "ok" at time of test- what a joke! Makes me mad that people get away with it I'll see you wed mate to give a little contribution to the build haha.

[mattg34]

Yes it 's me the owner! A blind ebay buy, would you belive it two owners in the same family. I love the car and thought it was definately worth preserving! Its only thanks to the main man Mark that its going to live!!

You've got to hand it to both Mark and the owner as well - I'd have been tempted to call the scrapper's van if my car was in that state

[markh]

Its definately getting there now Matt !!
The drivers arch is all welded up now, been skimmed with filler, rubbed down and primered.


Got the underside coated in spray underseal, fuel tank and refurbed axle beam ( A great job done by Matt on this) back in place, exhaust refitted and nearside side skirt back on. Still to do- Refit the re-painted rear shockers, bleed the brakes, new handbrake cables, refit the bodykit, modify a plastic BMW fuel filler neck to fit, paint the repaired area inside the boot and give the car a damn good clean inside and out. Sounds like a lot, but itl soon be finished.

[markh]

Matt, the owner of the car, came over from Tamworth this morning to help out with some of the work. We got the shockers back in, the handbrake cables in and adjusted, rear brakes adjusted and bled, the bodykit refitted ( fits like a glove, which is a relief after so much work !! ) and the rear bumper back on.

[The Autoad]

Lovely Mark

[markh]

Lovely Mark

Praise indeed from the Resto King !!! Cheers Ant.

[DT1]

Good to see it kept on the road, a lot of folk would just have scrapped it with that amount of rust.

[mattg34]

Well chuffed with all the work ,its looking like a scirocco again!Looking forward to get driving it again and get to some of the meets Having worked with mark today on it i realise what a genuis this man is, i wouldn't have stood a hope in hell of getting it back on the road again due to the extent of the rust. The rest of the car is great, the interior is mint and even before all the work was undertaken she drove beautifully. Im a happy man now not long to go

[markh]

Modified and fitted the BMW plastic fuel filler neck.

Modified the breather pipe at the top.

Put some fuel in the tank, no leaks from the filler neck and went to start the car. I had disconnected the battery when i started working on the car, but it just didnt have enough charge left after two months to turn the car over, so i've put it on trickle charge overnight. I got another coat of underseal sprayed onto the repaired areas and called it a day. Nearly there !