Ozonehostiles Blurple gti6.

[Niall]

Wow that is bad. I had my passengers sill trim off the car last winter and it was absolutely spot on under there. There must of been some sort of damage there on yours previous!
Scared to take my drivers sill off now!

[ozonehostile]

Horrible to find rust like that! But at least you know what your doing and your cracking on with the fix, good stuff!

Yeah man, not what I wanted to see when I was at the stage ready to insure it again lol. 

At least by fixing it properly first time I should never have rust issues again on this car, once the outer sill repair is finished I'll be pumping both sides full of waxoil 

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Wow that is bad. I had my passengers sill trim off the car last winter and it was absolutely spot on under there. There must of been some sort of damage there on yours previous!
Scared to take my drivers sill off now!

Yeah man, where the worst rust was you could just about make out a square hole like the head of an axle stand or something. 
Same on matts rallye too by the looks 

[Matt-Rallye]

Hurry up and finish it so we can do mine repairs looking good sir

[ozonehostile]

Hurry up and finish it so we can do mine repairs looking good sir

Just arrived at the unit for round 2  

Masking off the entire side first thing, welding splatter on paintwork is a definite do not want lol 

[ozonehostile]

Sealed all yesterday's inner sill repairs with zinc primer then a good coat of waxoil on top 



My old man came over for a look and unlike the first patch where it was plated he talked me into welding it butt to butt with the original sill  glad it was done now as it looks great and less chance of it rusting again since the biggest repair is flush with the original.  Ground it a bit thin on top of the first patch that will need touching up with the mig again and some work to do on the door shut but it's almost there  


Need to pick up a can of the original waxoil and an applicator gun then fill up the sill on both sides for extra future proofing. 

[ozonehostile]

She's finished! 

Did the final stretch of welding this morning with help from my mate at jamtech motorsport and my old man. All solid again, just need to stock up on some paint and bodywork items to get it all sealed and painted on Saturday. 

Anyway, the finished product 




This bit was the hardest  right up by the fuel tank elbow and return pipe and the metal was only about 0.5mm thick, having to deal with this as well as bridging a 5mm gap between the inner sill and the outer with barely enough space to get the welding torch in there 


Outer sill final plate cut to shape and best for a perfect repair 



I'll seam seal it all, underseal and paint tomorrow, then skirts will be reattached with some nice flush fitting nutserts for easy removal in the future 

[Piggy]

well done fella.

Glad you didnt scrap her, she looks ace when she's clean and all.

Good effort

[ozonehostile]

well done fella.

Glad you didnt scrap her, she looks ace when she's clean and all.

Good effort

Yeah man, I looked at what's for sale at the moment and tbh couldn't find anything better than what I already had so definitely worth spending the £100 or so on repair supplies. 

And since I have the welder all set up nicely I'm looking at my little rallye tucked up in the corner..... 

[Niall]

Glad you repaired this. Too many people scrap them and they are getting rarer and rarer. Plus it would be a shame to scrap a mint one!

[Piggy]

good lad, get on that rallye asap. I want a go!

[procta]

crackin repair job! at least you can still get the panels and donor sills, unlike mine sadly. I had a right f*ck on trying to get the repair panel for the sill.

[bashbarnard]

Good to see its not scrapped due to tin worm. So many people now see rust and get another one. Its a shame.

[ozonehostile]

crackin repair job! at least you can still get the panels and donor sills, unlike mine sadly. I had a right f*ck on trying to get the repair panel for the sill.

Now that the 306 is getting on a bit and had time to start rusting in weak areas I'm sure I won't be the last person having to do major repairs to keep them on the road. 

When they made 306 shells the entire side of the car is one piece spot welded along the roof and folded into the inner sill and pressed together at the bottom so they never made replacement panels for things like outer sills which is probably going to finish off alot of cars in the next few years

I luckily have a good network of engineering type people who were able to make me a sill repair panel from scratch 

[Dum-Dum]

The bonus of having a spare car or 2, can spend proper time on fixing the broken ones.

Hope you start the 106 rallye soon.

[7057sam]

Well done mate,looks great

Now do I dare take the skirts off mine.....

[ozonehostile]

Managed to get in a full day doing all the time consuming parts of finishing off the repair job today:

First up I sanded Down all the visible parts in the door shut and filled the weld to get the finish as smooth as possible, little
 bit of distortion where it's been welded but that can't be helped. 

Applied a bead of seam sealer to all the lines of weld just for extra future proofing 




Matt came over for a bit and gave me a hand masking off the side of the car and the first decent layer of primer on 


My new favourite toy, nutserts! 

Figured for future side skirt removal these are ideal, got a load of m5 stainless cap heads and washers so should look good when fitted too. 



Inserts in place 


Need to find some panel wipe from somewhere tomorrow morning and then put a coat of nile blue on then get the skirts back on both sides with the new and improved quick release setup  

[Piggy]

Oh damn! I'd love one of that tools!!!

[ozonehostile]

The bonus of having a spare car or 2, can spend proper time on fixing the broken ones.

Hope you start the 106 rallye soon.

Rallye is next in line since all the welder and supplies are still stocked up  

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Well done mate,looks great

Now do I dare take the skirts off mine.....

I would haha, better to know if there's anything lurking under there before its irreparable. 

Hopefully nothing though, cracked skirts on the underside seem to be the tell tale sign that it's been jacked incorrectly 

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Well done mate,looks great

Now do I dare take the skirts off mine.....

I would haha, better to know if there's anything lurking under there before its irreparable. 

Hopefully nothing though, cracked skirts on the underside seem to be the tell tale sign that it's been jacked incorrectly 

[Matt-Rallye]

Sorry i couldnt stay longer dude but was good to have a catchup with yourself and the '6

[ozonehostile]

Finally got around to pressing the powerflex bump stops into my new cups from spoox, probably won't make any difference at all but at least they'll look pretty under the car 


Matt came over again with his paint expertise and got some colour onto the repaired sill, going to need a lot of wet sanding before I'm happy but worth it in the long run hopefully 

[Dum-Dum]

Not sure I'd be too worried about how perfect the colour is if it's going to be hidden behind the skirt.

[Matt-Rallye]

Not sure I'd be too worried about how perfect the colour is if it's going to be hidden behind the skirt.

Remember that is captain OEM your talking too.. if it was me i would of just matt blacked it and banged the skirt back on!

[ozonehostile]

Not sure I'd be too worried about how perfect the colour is if it's going to be hidden behind the skirt.

Remember that is captain OEM your talking too.. if it was me i would of just matt blacked it and banged the skirt back on!

Aha I did think about just painting it black kind of like a ph1 with the two tone side skirts but then thought if it's worth repairing may aswell do it properly, I want it to look like it's never had any work done on the sill. 

Probably not going to be perfect with Rattle cans but good enough for a part you're not even going to see

[Matt-Rallye]

306 & 106 rallye next for the welder i believe sir you need to hurry up and get a better job so your free in the evenings and buy a megane... all the best people have them i hear

[Orta]

That looks a fair decent job mate. Good to see the '6 in one piece so it'll be @ FCS. Unlike sum other 306s from Hereford !

[ozonehostile]

That looks a fair decent job mate. Good to see the '6 in one piece so it'll be @ FCS. Unlike sum other 306s from Hereford !

Ahaha, well it's becoming a joint effort of sorts now to make sure at least the one Xu10 powered 306 makes it from the shire

[Matt]

Good work on that sill! And I love the new quick release setup you have going.



Also can't wait for your rallye to be back

[Matt-Rallye]

That looks a fair decent job mate. Good to see the '6 in one piece so it'll be @ FCS. Unlike sum other 306s from Hereford !

Bellend

That looks a fair decent job mate. Good to see the '6 in one piece so it'll be @ FCS. Unlike sum other 306s from Hereford !

Ahaha, well it's becoming a joint effort of sorts now to make sure at least the one Xu10 powered 306 makes it from the shire

Basically mine needs all the prep we did to yours when you bought it last year

[ozonehostile]

Got the first coat of laquer on the other night, looks pretty good  

[ozonehostile]

I've had a rallye aux setup sat in a box for over a year now that I have yet to fix so made a start on getting all the broken aircon components out and cleaning the engine bay as I go. 

The rad will be replaced with a new alloy one, slimline fans to get rid of the heavy oem ones and I might make a bracket for my oil cooler. 

Using the left over nile blue paint to clean up some flakey paint on the inner wings and bulkhead