Winter project

Mike Schofield

Mike Schofield

True Classic
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Going to dive into the rot in the trunk floor this winter. Here are some “before pictures”.
 
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Been there, done that. It is a challenging rust replacement project, with many different possible fixes. Have fun with it!
 
That looks almost exactly like mine does. Funny because there is very little rust on the whole car, except for this in the trunk and one or two very small places (and those are surface only). But all the other typical problem areas are completely free of any rust. That trunk sure was a magnet for it.
 
I gather you have already attacked the trunk floor since one photo shows it missing. My 77 looked like that, the floor was really bad on the left half so I cut it out and replaced a flat sheet of 22ga metal. The Bertone was so bad I cut the whole thing out and decided I liked the rear with no trunk floor and no rear firewall. It's a good area to practice rust repair and panel replacement.
 
Yes, I have already cut the floor out. Start fresh is my modo! Overall, it was mostly the panel itself that was rotted. The “framework” just has some surface rust but shouldn’t be much to clean up. The rear crossmember is mint thank god! The plan is to fabricate a removable bead rolled stainless panel. Also, to start fresh with the exhaust. Stainless Header to a flowmaster super 44 is my plan.
 
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Some more progress on the project. Removing remnants of the old floor panel and cleaning up surface rust/ repairing rotted areas.
The air chisel made short work of removing the spot welds.
 
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Mike Schofield said:
Talk about opening up a can of worms!
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Mike I have some repair panels for you here. If you need the right side with the exhaust pipe notch I have the hammer form here. Just come down and I will set you up and you can beat out a repair panel for that side. I also have the trunk bottom hammer forms here as well.

TonyK.

Grimsby Ontario Canada.
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Ya, not sure what happened but the front of my car is in really great shape but the trunk took a beating! Moreso on the left side.
Bondo repairs bother me.....body filling to smooth out imperfections in one thing but to fill holes? Bad business...
 
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Recently acquired a used rear lower valence from a kind xweb member. Was in great shape but had accumulated layers of paint etc in its lifetime. She’s now sandblasted and painted with a good substrate. Will need some further massaging but overall I’m happy with it so far.
 
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Mike Schofield said:
Recently acquired a used rear lower valence from a kind xweb member. Was in great shape but had accumulated layers of paint etc in its lifetime. She’s now sandblasted and painted with a good substrate. Will need some further massaging but overall I’m happy with it so far.
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Was that Donny? Good guy!!
 
TonyK said:
Mike I have some repair panels for you here. If you need the right side with the exhaust pipe notch I have the hammer form here. Just come down and I will set you up and you can beat out a repair panel for that side. I also have the trunk bottom hammer forms here as well.

TonyK.

Grimsby Ontario Canada.View attachment 16627
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I ordered the heel pans from Bayless and my trunk pan from Eurosport! Had I known, I might have been asking if I could swing by!!
 
Unlike a BMW where the turn signals are optional and rarely ordered, this is a factory forced feature on all X1/9s.
 
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