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August 5, 2023

Rust Diaries, Day 16: Truck Bedliner

The work’s picking up pace. Today, we opened the first can of Cobra – a textured truck bedliner coating based on two-component polyurethane resins, which is going to make the final layer on the underside of the car. I was a bit apprehensive about this moment and wasn’t sure how RAL 5017 would look on the car. But I think it turned out quite well. Yes, it’s brighter than 02C - World Rally Blue, but once everything that the roads have to offer covers it, it will look class. Cobra on the rear wheel arches and up to the gearbox line:

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August 4, 2023

Rust Diaries, Day 15: Subframes II

Following up on the work done on Day 12, we continued with all the large parts that didn’t make it to the powder coating: Dinitrol and the primer.

I spent some time and effort on the lateral link set — steel wool works wonders on those aluminum pieces.

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August 3, 2023

Rust Diaries, Day 14: Halfway point (?)

The theoretical halfway point (I gave myself a month to finish this), but we’ll see how it turns out in the end. The engine bay won’t be stripped; we wouldn’t have had enough time, plus some of the work required could have been too much for us to handle — like rerouting the fuel and brake lines. After all, our technical consultant deserves our respect and we would not want to over work him. As a result, brown packing paper in hand, it’s time to start packing things up. We’ll finish stripping at the chassis beams level.

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August 2, 2023

Rust Diaries, Day 13: From big to samll

The next logical step was to tidy up all the remaining small parts, and that’s exactly what we did. Quite a few of them went through zinc plating.

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July 30, 2023

Rust Diaries, Day 12: Subframes

During the break from the sheet metal on the underside, we tackled the bigger parts: subframe, trailing arms, differential and driveshaft mounts, sway bar — basically everything we could get our hands on. The only difference was that all those parts went straight into sandblasting. As the car had only 56,000 km on it, the bushings were in very good shape, so we decided against powder coating the parts with the bushings, as it would ruin them in the process–for those it was the usual treatment Dinitrol and Interplus. There’s something to be said about those OEM parts — sure, you could replace them with the likes of Powerflex, but that didn’t feel right. Everything else was powder coated, though.

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July 26, 2023

Rust Diaries, Days of abrasion

The first grinding sessions quickly turned into worn-out discs, bald brushes, and soot-covered faces. The days blended into a blurred continuity, punctuated by Dinitrol and Interplus 256. Our best friends became the angle grinder and the power drill. For the most stubborn areas, we resorted to sand blasting, but that was definitely the minority.

I like this picture quite a lot; it shows the stages nicely: in the middle, bare metal; to the right, covered with Dinitrol RC 900 – rust converted and primer; and finally, on the far right (ahem), still untouched.

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July 24, 2023

The Goodies

In the meantime, the goodies:

Oil pressure and temperature, as well as turbo boost from Defi, in the ATI gauge pod. That pod was really hard to find; I tracked it down in the Netherlands.

For completeness, the console, all the sensors and the wiring:

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July 19, 2023

Rust Diaries, Days 4 and 5: Brushes

Some conceptual work, preparation for cleaning, and testing of various wire brushes and polyamide abrasive discs were done.

The car’s body was wrapped to protect the paintwork and then moved under the shelter.

We also managed to disassemble the rear axle.

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July 17, 2023

Rust Diaries, Day 3: Rear suspension and fuel tank

It’s warm, so the car is melting quickly. Today, we dismantled the entire rear suspension: struts, springs, brakes, axles with the differential, the fuel tank, and the rear crossmember. The work is going surprisingly well; Tomek’s dad is well skilled.

On the downside, we snapped two bolts — one from the diff mounting and one from the rear suspension trailing arm. There’s a nearby access hole, but we don’t have much hope for success.

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