Red Rallye resto

[Ben_w]

Today was about three things.

Cider hangover…….good time seeing our best friends yesterday night for dinner and carried on when we got home!

Grinder shopping

Stripping!

So, have got to Argos at 10:45, not realising it didn't open until 11 and being shocked at just how many people were there waiting, grinder was purchased and i was on the way home.

First things first, brew. Tis the law on a Sunday morning when you might not be feeling your best! Brew done and outside to get busy.

First job was take the subframe, hubs and struts off, again! The bits i zinc plated myself have held up very well indeed, I'm very happy.



[seeIMG]http://i222.photobucket.com/albums/dd238/ben_wells77/Mobile%20Uploads/2017-04/IMG_20170402_124330_zps1tsvkdab.jpg[/IMG]

This is as far as i got before…..



Anyway, i got busy firstly on the passenger side arch. The one big issue with the Rallyes seems to be the hidden rust. There's that much seam sealant/stone chip under there which looks fine on top, but underneath it's a different story. This is by the welded in bracket that hold the brake flexible pipes. I took this pic as i stopped with the grinder as it was a good opportunity to show what's going on. Remaining seam sealant/stone chip looks fine but you can already see the rust underneath



A bit more wire brush and this….



Worrying in that there don't appear to be any bits where the water could have got in. All the more reason to bare metal. A smaller wire brush in the drill gets it to this.



I'm very tempted to have the place i will take it to to be blasted/2k primed drill the spot welds and remove the brackets, clean up underneath and then reweld them in place. This OCD is getting out of control.

Moving on a bit, still in the same arch, i came across this not far away. Spotted this in an instant (I'm such a geek…)



Didn't get an after pic but looks like a stone chip (hole in the middle) has let water in and it's got underneath. Didn't get an after pic but there was surface rust the size of the blow on the sealant.

Got bored with the arch and lying in the floor so parked my ample arse on the front cross member and started on the engine bay. Ended up looking like this..



But not before I'd found this on the passenger side bulkhead



Or this under and to the right hand side of the servo..





In for a penny, out came the screwdriver. Bugger.





Clearly water ingress although you can see from the angles of things here that water will collect and just sit. Poor design Pug, poor design. Then got busy cleaning up the floor sections i couldn't do before when the subframe was on. No real issues here, just more of that black crap





Need to find a way to pop these back out…..eejits with trolley jacks..





Got to 6pm and i called it quits. Ears ringing as i forgot how loud the wire brushing could be, must buy some ear plugs. Still, I'd had most of what was a very nice day, outside, doing what i love!