The Ultimate X - Fiat X1/9

[Mark Bowden]

Could you send me details as well if it's still available.

Many thanks

Owner of the stalled Dallara build: Julian Brown 07973 217328

 

[Mark Bowden]

Could you send me details as well if it's still available.

Many thanks

The owner of the stalled Dallara build was Julian Brown 07973 217328

 

[Mark Bowden]

I spent a few hours looking at the areas where the front suspension turrets have rotted out.
It looks like moisture got trapped between the bottom of the turrets and the sides of the front luggage compartment.
The sides of the compartment are the frame and the inner wings are the skin.
These are spot welded to form a complex shape.
Along the lower edge it's basically a square section joining to the bulkhead, and is inline with what develops into the front leg, ending with the bumper mount and tow eye.
The turret is pressed from a thicker gauge steel, spot welded to parts of the inner wing or compartment frame, to form 2 or 3 layers.
The square section part along its top and outboard side, and most of the inner wing, and some of the lower part of the turret is completely gone, and peeling away being forced out by layers of inaccessible corrosion.
Next step is to cut away all the rubbish and make some patches.

 

[EF Ian]

Rust is such a curse.

 

[svensktoppen]

All old cars have it somewhere if they've lived in this country. It's pretty much unavoidable. It's just that most people cover it up, polish the paint, and move it on as "mint", lol.

Nice to see people making the effort doing it right and preserving for the future. There are a few projects like that here now. How things have changed from the days of wild tuning and skidding on dinner trays in car parks

 

[Mark Bowden]

Haha, as it happens I watched a video last night and I had to recalibrate my definition of "doing it right".
I'm going to have to get some help I think I can talk to a couple of people, they might say you can do it yourself with one of these, they only cost X amount etc.
Right now I don't have a clue what type of welding process is best for, let's face it, metal ranging in thickness from very thin downwards.
I would be happy if the end result was just, strong.

 

[Mark Bowden]

Rust is such a curse.

Totally agree, beyond a certain point it's hopeless.
I remember you said something about adding a drain pipe from the gutter.
I don't think it's possible because the gutters don't end up joining to make corners where pipes could collect in a sort of T. arrangement.
The nose gutter and wing gutters drain in to an area framed by a pressing called 'headlamp access frame' which has a pressed non watertight cover called 'headlamp access frame cover', which has to be removed completely for changing the bulbs and the cover is outboard of the bonnet seal.
I could do with some custom 20mm electrical tape, in Rosso Corsa with 4mm black "perfect panel gaps" TM centre stripe.

 

[Mark Bowden]

I decided to cut out the entire affected area on account of corrosion build up between the different pressings and between different layers of filler and fibreglass.

Next step is to work out the welding sequence and make some patches.

 

[EF Ian]

I don't envy you.

 

[Mark Bowden]

I made some patch plates out of 2mm zintec and...not much else

 

[Mark Bowden]

Front offside wheel arch and suspension turret.

 

[svensktoppen]

Coming along

 

[Mark Bowden]

I've spent a considerable amount of time in awkward positions scraping multiple layers of crud, paint, underseal etc off the underside of the front luggage compartment floor, a job I was dreading.

Almost surprisingly for some reason, this area was mostly in good condition, apart from where the floor joins the front bulkhead immediately below the screenwash pump, probably what caused the corrosion.

Then 2 coats of grey etch primer (tin#6 can't believe I've used 5 litres on the car already)...

 

[svensktoppen]

Not a nice job to do, but nice when you see the result Came out well there.

 

[Mark Bowden]

Not a nice job to do, but nice when you see the result Came out well there.

It's oddly satisfying removing horrible black gak like you say.
Later on when I fit the suspension I won't be regretting its absence

 

[Mark Bowden]

A while back I realized: before I could build the front suspension I would have to finish the nose, because the stands make working on the nose impossible.

Having prepared and primed the areas I could reach with the front supported on a wooden frame, I refitted the steel lifting beam and stands, dismantled the wooden frame, and generally reconfigured the working area so I can access the remaining front floor area.

The adapted bumper irons that screw into the tow eye inserts, worked a treat despite the clearance between the nose and beam is... minimal

 

[svensktoppen]

I quite like those lights now they are coming together, look good there. Certainly different

 

[Mark Bowden]

I will be happy if they do the job and are an improvement.
At the moment it's fingers crossed pending the final adjustment.
The most obvious thing cosmetically, might be to spray the top covers the body colour, which was my original intention.
I guess it's one of those subjective yes/no decisions

 

[Mark Bowden]

I had an idea the steering rack tunnel would be an ordeal, probably why I've been avoiding it for years
It would be difficult even if the car was on a rotisserie and the rack removed, but no such luxury.
I eventually managed to chisel off all the old underseal, revealing the usual pattern of surface rust along the seams and the odd hole but overall not too bad considering.
I imagine many an X1/9 with advanced rot in these areas, was scrapped, so in some ways I count myself lucky

 

[Mark Bowden]

First coat of marine gloss...

 

[Mark Bowden]

Front wheel arches continued -
- Patches complete
- Turret plates bonded to body
- Top mounts temporarily fitted

 

[Mark Bowden]

Continued front ARB, front reaction struts, front control arm ball joints, ARB to control arm bush assemblies...

 

[Mark Bowden]

 

[EF Ian]

Making good steady progress on this. Arms all look great.

 

[Mark Bowden]

Making good steady progress on this. Arms all look great.

cheers