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S3 109 Safari project......

Discussion in 'Members Vehicles/Projects' started by GSF 109, Apr 3, 2020.

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  1. GSF 109

    GSF 109 Active Member

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    Hi all, thought I had better post some pics of my latest folly, my 109 SW project...

    It didn't look to promising in the Gumtree ad. In fact they guy was actually selling another SWB and he though I was joking when I said I wanted to buy the one behind it in the picture!
    Anyway, a deal was done and I got the pile of bits delivered the following week. 026.JPG 028.JPG
     

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  2. GSF 109

    GSF 109 Active Member

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    Thought I would get it stripped down to bare bones and start some major surgery!:D
    The wee guy gave me a hand with some painting post surgery.
     

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    Last edited: Apr 3, 2020
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  3. GSF 109

    GSF 109 Active Member

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    IMG_1857.JPG IMG_1859.JPG IMG_1860.JPG IMG_1861.JPG IMG_1863.JPG IMG_1891.JPG Started with the rear crossmember replacement using the rear body as a jig. Then moved onto outriggers and springhangers. Made up some brackets for the seatbelt mounts. Then moved to the toe board outriggers. Again used and standard LWB outriggers and made the brackets to replicate the originals. If you want to see more, let me know - cheers!
     
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  4. stevema

    stevema Member

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    That's a project for sure! Will be lovely when done
     
  5. GSF 109

    GSF 109 Active Member

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    A few more pics of the chassis work....
     

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  6. GSF 109

    GSF 109 Active Member

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  7. GSF 109

    GSF 109 Active Member

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    Some more chassis work.... 1BF4E996-A50D-449C-844F-204745EBE768.jpeg 62794732-0265-49AE-A115-2321F66C4B36.jpeg C981F6E2-A6E7-4BFF-ABE4-CE076A1D2475.jpeg 239DACFB-E95F-42C5-9497-3A5764103D27.jpeg 1C87B3E3-D6DE-47BB-87E1-863AD42900ED.jpeg FF3F69DF-5D32-49D7-B9CB-B3F0E3EE64B9.jpeg 49714E79-41E0-495F-B373-0032AE1B5A65.jpeg
     
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  8. GSF 109

    GSF 109 Active Member

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    The o/s bulkhead outrigger was totally sound except for the top section so the plan was to replace that part only. Unknown to me the outrigger had its own pond inside complete with tide marks!
     

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  9. GSF 109

    GSF 109 Active Member

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    After draining, cleaning internally and priming, I fabricated and fitted a repair section.
     

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  10. GSF 109

    GSF 109 Active Member

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    Cut some angle iron to replace the bulkhead outrigger braces to replace the rotted out ones. 91C5F718-2140-4D70-BCD7-B8ED8BE9CBAD.jpeg 3535318A-BC16-479A-90AC-4DA489DF4ACB.jpeg 80DBD402-3153-47A5-809B-C5C89B3E21B6.jpeg
     
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  11. Knappster

    Knappster Well-Known Member

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    Looking good!
     
  12. GSF 109

    GSF 109 Active Member

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    Thanks for the positive comments! I’m starting to see it turn from a lump of rust to something resembling a solid chassis. I will move onto the bulkhead next and see if I can turn the sorry mess it is into something decent. I am also going to investigate doing a power steering conversion.... just in case I get bored ;)
     
  13. Anchored

    Anchored Member

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    And I thought I had a project! At least my chassis is sound, what paint have you used as your primer?
     
  14. GSF 109

    GSF 109 Active Member

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    Hi, yes it’s a full on project for sure! I starting to show some progress now though. I will post some more pics soon. It is corroless primer. I swear by it to be honest. I bought it from arc-rite paints. I have the black topcoat for it too.
     
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  15. Anchored

    Anchored Member

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    Thanks pal, much appreciated.
     
  16. GSF 109

    GSF 109 Active Member

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  17. GSF 109

    GSF 109 Active Member

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    Bulkhead doesn’t look to promising but it is saveable. Got it stripped ready for foot wells, pillars and patch repairs...
     
  18. GSF 109

    GSF 109 Active Member

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    Footwell repairs started! 38594F22-37E3-402F-A352-1B6361B7D679.jpeg E3A47496-8ECE-447C-9D97-545A667CBBB6.jpeg 17C2974C-99D8-4A03-8587-A17C9781D859.jpeg 7BEDD636-1D43-4819-B1B2-F5A3378F2EFF.jpeg DB8BAEB8-294F-48B4-BAA8-81F3181EDEFF.jpeg 04C4833B-5116-452D-A2E9-AA6E536756FD.jpeg A73A7AF3-1A0A-4889-A833-2BAA93EBD372.jpeg 04CDBAD1-4915-4EFD-BDF0-C3841323A866.jpeg
     
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  19. GSF 109

    GSF 109 Active Member

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    The ‘A’ pillar repair section was not ideal as the fold where it meets the footwell was folded 5mm out! No wonder it was cheap on eBay! I had to straighten the fold, then bend it again, but in the right place this time. Lesson learned regarding ‘cheap’ panels!:mad:
     
  20. GSF 109

    GSF 109 Active Member

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    9586C69F-1E3F-4B6F-B97A-B956339A5826.jpeg 83AFD6F6-B429-402C-A3B3-09034D8D63B2.jpeg A077E103-0585-4A01-A993-3486FFD35B47.jpeg 47CA76B2-1830-4046-89DD-696247F37470.jpeg
     
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