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Derek
V4 Guru

United Kingdom
1782 Posts

Posted - 07 Sep 2017 :  11:04:10 Show Profile Reply with Quote
Burdizzo?
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72sonett3
V4 Fanatic

Spain
203 Posts

Posted - 07 Sep 2017 :  17:00:44 Show Profile Reply with Quote
quote:
Originally posted by Dynorog
...
I'll get hold of some 1.5 mm plate as martin suggested and fab up a new plate.

I had to repair this exact same spot in both my '77 96 and '98 95.

First I cut out the rotten sections like you did and cleaned the edges to bare metal.
Then I traced the size and shape of the hole on a piece of cereal box card board and used that as a template to cut the shape out of a flat metal sheet, and bent it to the shape of the hole in the body.
Then first tack welded it in place followed by continuous butt welds (= without overlap) all around, not all in the same spot but spaced about 10 cm around the edge to avoid build up of heat.
Then some cosmetic grinding and shaping of welds where needed, then primer and finally under body coating.

Remove the carpets and rubber cover of the wheel well in the interior before you start welding... !

--
'72 97
'77 96L conv.
'79 96GL (LPG)
'83 900i (LPG)
'95 900SE conv.
'99 9-3T
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Dynorog
V4 Beginner

United Kingdom
64 Posts

Posted - 07 Sep 2017 :  18:26:29 Show Profile Reply with Quote
quote:
Burdizzo

I think my wife will use it as one if I spend any more time working on the car!

Dynorog
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deggsie
V4 Fanatic

United Kingdom
287 Posts

Posted - 07 Sep 2017 :  18:32:35 Show Profile Reply with Quote
Originally posted by Dynorog
Burdizzo - I think my wife will use it as one if I spend any more time working on the car!


Not a term I was familiar with, so had to look it up ! A tool for nuts of a different kind, I see (although there is also an Italian wine of the same name)!

___________________________
Saab - beyond the conventional !

Edited by - deggsie on 07 Sep 2017 18:51:05
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Dynorog
V4 Beginner

United Kingdom
64 Posts

Posted - 08 Sep 2017 :  18:45:09 Show Profile Reply with Quote
Thanks for the tips Martin.
Why did you go for a butt weld instead of the lap?
Cheers

Dynorog
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72sonett3
V4 Fanatic

Spain
203 Posts

Posted - 09 Sep 2017 :  16:50:20 Show Profile Reply with Quote
The overlap will be a source for corrosion, specially in that area.
I prefer butt welds, even if it may be a bit more difficult to do, but after some trials you will get the voltage and current settings right.

--
'72 97
'77 96L conv.
'79 96GL (LPG)
'83 900i (LPG)
'95 900SE conv.
'99 9-3T
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Dynorog
V4 Beginner

United Kingdom
64 Posts

Posted - 09 Sep 2017 :  19:02:11 Show Profile Reply with Quote
OK, thanks Martin
Cheers

Dynorog
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RhysN
V4 Fan

United Kingdom
123 Posts

Posted - 15 Nov 2017 :  17:18:27 Show Profile Send RhysN an AOL message Reply with Quote
I had a very pleasant afternoon visiting Roger and his project. It's almost enough to frighten you (me) off when I see how much he has had to do on a car which obviously seemed pristine in the first place. He is a real enthusiast, and a thoroughly "good bloke , or good bugger". (High praise in the Antipodes)
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