"Restoring" the bumper

 The rear bumper is in bad shape it is bent and rusty, started with straigtening it in the shop press.

The corners where totally rusted out! Only the crome made it look intact. Cut out the rusty part to have something to weld to. Used 3mm flatbar so I have enough material to grind the shape of the bumber.

One corner welded and grinded.

Same procedure on the other side witch is in worse shape.

Several pieces where needed here.

Roughly grinded in shape

Bumper fastening brackets painted.

Inside of bumper painted black.

Visible side of bumber is grinded down and covered with clear coating. 

An alternative here would have been painting or wrapping witch would have enabled use of bondo to cover remaining imperfections but I will try it like this as I like the fact that repairs can be seen. I can always paint or wrap later if I feel like it.

"Paint booth"

left to dry over night.

Reassembly of fastening brackets.

Fastening of plywood for seat and backrest

Fastening the backrest. 

Started with drilling 9mm holes in the frame. Aimed to get the holes in a straight line and with even spaces inbetween.

Clamped the backrest and drilled 8mm holes true the plywood.

This is the M8 threaded hardware used.

Backrest installed.

The plywood is covered with mold protective coat of "saunasuoja" with brown pigment.

Next up for backrest and seat is upholstery.

Trim

 Starting point.

Tried to straighten and hammer out the dents in the trim. Sanded down i three steps, first 240 grit paper then 1000 grit and last with 2400 grit paper.

 Finished of by Pollishing.

Still looks quite bad but at least its shiny!

 

More work on the back side of the sofa.

I made a tool to "counter sink" screw heads with. 

A 5mm hole is drilled in the sheet metal witch is same as the steering pin on the tool. Sheet metal is placed on the tool and the you hit the counter piece with a heavy hammer. 

The result is not perfect. The raised part is a bit shallow. I might do some more adjustments before final assembly.

Details on back side of sofa.

What is back and forward on this project is a bit difficult to define as the back of the car is the front side of the sofa... But any way the side that will be facing the wall at some point looked unfinished at the lower corners and open ended subframes.

Welded some plates to the "back" corners of the sofa. Not only will it look better when ready but it also strengthened the corners. 

Subframe ends where welded shut.

More grinding and welding will be needed before ready.

Mock up to get an idea of what it will finally look like.

Rear valance panel

Unsure of what the correct name for the part is but after some searching "rear valance panel" seems to be correct. On the donor car this part was removed as a hole. My guess is it was in a decent shape when the car came to the scrapyard and has therefore been thoroughly removed. 

Rear valance panel welded in place

Before

Decided to go for a easy design not trying to make a stock looking panel as it will probably be unnoticed by most on the ready product. The initial shape was created with a brake. The radius became to small so some adjustments where needed.

Determining the shape.

Radius adjustment tool kit = big hammer and 2 by 4! 

"Back" side of panel was painted before welding in place.

Welded in place.

To stiffen up the rear valance panel a strengthening piece was made with holes in it for decoration even if no one will ever see it.

Used a flare die for added character.

 

Welded in place.

Bumper mocked up to see what it will look like when ready.

More and hopefully final rust repairs.

There are a few weak and crusty spots that need attention. Some of these repairs where done already during the winter and some are made now. Didn't take pictures of all the patches.

Left quarter panel. 

There is also a patch on the inside.

Some patches here and there...

 

There is still some welding to be done that I will revert to in some coming post but I consider the actual rust repairs to be done now.