1994 Range Rover

[TerryG]

I had a man come and depressurise my air conditioning this morning. I had read through the instructions in the manual a few times and it sounded pretty easy to get the heater unit out............. 4 hours. 4 HOURS!
When the instructions say "ease the heater and cooling unit from the vehicle" it should say "using a pry bar shake, wiggle, lever and wrench heater and cooling unit from the vehicle".
Anyway, now that is out I added a small amount of metal:

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but more importantly, this is the rust hole that has been worrying me. After adding the new metal at least I can push down on the middle of the scuttle without it moving.

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[TerryG]

Today's instalment of rust removal.
I pulled the sound deadening away properly and this is what I saw behind it

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So out came the grinder

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I did cut some more out but the pic is really blurry

In went some new metal

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And some more

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And even more

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This is the outside view of the most awkward panel to date, it is S shaped left to right and C shaped top to bottom on one side and straight on the other.

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All packed away now. I spent almost an hour taking the steering column support frame apart so I can get at the drivers side of the scuttle properly. It isn't quite as bad as the passenger side was but will require the same repairs. Weather is supposed to be wet and horrible for the next few days so progress will slow down

[JPB]

Wow! Immense progress there Terry, especially as you've not been welding for that long. There's some real talent coming out there.

When this is done and the car is all reassembled and back on the road you'll be driving it around with the widest ever grin on your boat simply because you'll know that very few are as solid in these hidden, usually neglected areas.

[arceye]

WHS ^^^^^

This one will be as solid as they get at this rate, good effort Terry, I've seen people with a lot more experience with a welder run from jobs like this one.

[TerryG]

Thanks for the encouragement guys. I don't mind having a go at any job but this is so time consuming. Hopefully I am 2/3 of the way to having a waterproof car again. Still lots of past bodges to fix after that is done but at least I can stop worrying about the interior getting ruined.
I have put the feelers about for replacement front carpet as mine is rotten and split where I pulled it back. Hopefully I can find one in the next week or so, that way I get the car back on the road again .

[Richard Moss]

When you look at this thread, you have to wonder if the bodies were built by Alfa Romeo or FIAT on a sub-contract.

[TerryG]

On and off rain today so I did get some done just not as much as I wanted to.
This is what I found after some poking about

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So I got out the grinder

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Then I filled it in again (ignore the duck tape, I had to rapidly waterproof the car when it started chucking it down)

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Hopefully the rain holds off tomorrow so I can finish the scuttle. I have got to do more or less the same repair to the drivers side as I did to the passenger so that will take a few days more. I have almost finished my first 50x100cm sheet, only about 30x20 left to go, I may have to go and get some more!

[TerryG]

Got a bit more done today.
I filled in the holes that until yesterday were filled with tape

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Then I thought I would make another hole

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I didn't like having that particular hole there so I filled it in again

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I also filled in the funny shaped bits left along the bulkhead and plug welded through between the two panels that make up the scuttle. Then I cut out the holes to the correct size and shape for the A/C lines and heater hoses.

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Amazingly there are no holes other than the ones the manufacturer put there (there will be next week when I start on the panel down the drivers side)

[TerryG]

A little bit more done today and have learnt 2 things.
Firstly, when you think you have removed all the sealer and underseal from where you are going to weld, you haven't. I will have to get some thinners to try and remove the waxy stuff tomorrow as I wondered why my welding suddenly went all spattery and blobby. On the plus side if I ever run out of fire lighters I can always get the waxoil out of the garage :S
Secondly, the foam rubber "pads" you can buy to lie on while working under the car are not flame proof. They burn almost as well as waxoil does. I need to buy myself a new one now

Anyway, after some poking on the drivers side what I thought was metal proved to be seam sealer.

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As least this is traditional outside in rust so you can see where it is rather than the floors which went outside in so looked perfect when inspecting them.

Some grinding and I had a new bigger hole

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I filled some of it in before starting a fire and deciding I had enough for the day.

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The hole you can see in the floor is what I thought previously to be solid but was actually rust supported by the mounting bracket for my side skirt.
Other little jobs done include re-installing the cold air duct, wiper motor and all the little studs that things like the fuse box, ECU, sound deadening and various other bits screw to that I removed with grotty metal over the last few weeks. I am guaranteed to have one or two in the wrong place and they will almost certainly be the most awkward ones to get at but I will cross that bridge when I come to it.

I have also tried re-fitting the steering column which is very awkward and heavy so may have to wait for my brothers visit this coming weekend for a hand in getting it coupled to the shaft properly.

[TerryG]

Progress is slowing down but I am still making some. After some running around and getting an MOT for my proper classic I attacked the range with my handy grinder and...
Inside view

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Outside view

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I did put some metal back in.

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This still needs welding across the top. That is the first job for tomorrow. I opted to fix the corner first so I have something to line up the floor with. Fingers crossed once I have done this bit I will be able to fully re-assemble the dash. The whole front panel and the very front of both inner wings still to do then I can put the wings, bonnet and scuttle cover back on properly. I might even go for a celebratory drive. I am touching wood and hoping it will be drivable by the end of the week.