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Unbelievable this car was still on the road last year and made it safely to the Sharknose Meeting, such a shame for such a nice car. I'm a big fan of E9's, like the 2000C(S) the most.
Is it the Polaris paint that make these cars so rusty?

But now it's in Ben's good hands,

What kind of welder are you using?

And now onto the front end of the sill:


cut out to better metal:


small repair to the floor and inner sill:


The the rest of the inner sill and a bit of box for the jacking point (normally this is not in an E9 but we felt after seeing the structure for the rear jacking support it made sense):



and then the section of the intermediate back on:


Then the bottom of the A post and door frame:

Then the outer sill just tacked on for now:





Then we started on the other side which needed a repair to the bottom of the B-Post:

Should of mentioned that weld through zinc primer is being used inside the sills before the outer went on:




And that brings us up to New Years 2016/2017.

Cheers

Ben

Great progress! This is the only way to weld it proper.

rust bucket is turning to just bucket

are you planing to zinc bath the bare shell as you did e21?

BertjeConti wrote:Unbelievable this car was still on the road last year and made it safely to the Sharknose Meeting, such a shame for such a nice car. I'm a big fan of E9's, like the 2000C(S) the most.
Is it the Polaris paint that make these cars so rusty?

But now it's in Ben's good hands,

What kind of welder are you using?

I'll have to check what the welder is? What I do know is that it is MIG, has a big internal inverter so doesn't overheat with prolonged use and also uses a large reel of wire (IIRC 10kg). Its on wheels for easy movement around the garage, we also needed to fit a 40amp armoured supply cable and breaker for it.

Mihajlo wrote:

rust bucket is turning to just bucket

are you planing to zinc bath the bare shell as you did e21?

Yes, when we finish all the metalwork repairs it goes back for another chemical dip then Zinc Galvanize'd bodyshell and e-coat'd panels.

Found the info on the Welder:

SWP redline mig 210amp turbo
with 15kg reel of 0.8mm wire

from here:
http://www.ebay.co.uk/itm/SWP-Redline-M ... 3641.l6368

Cheers

Ben

A lot of work already. But I see many more. Good job.

Is getting better and better!!

Unbelievable show of skills and a mammoth task. I am so glad it is in such good hands! I had a CSI in the 70's in Germany- absolutely loved it

Great work so far. The e3 me and Nas are restoring also needed a fair amount of metal work. Good idea about the ecoating. The e3 was dipped and it,was well,worth the money.

Both rear arch lips have been repaired in the past. Not to our liking as they were welded over the top of the original panel with a 2 inch overlap:


So these were cut off and front quarter sections let in along with repositioning the outer arch repairs:

We then moved onto the rear floor repairs:

Front floors: