Series 3 109 Station Wagon, full ground up resto and 88 redo careless resto driving project

Although the vynal shifts well over the repaired foam. It is slightly shorter than the surrounding original factory foam .

My concern is that it may sink a little over time and use, so I'll fill it lightly and see how that feels.

Actually it's around the needs foam

But I will use a fine fill
Since it's impossible to get a completely flat finish between new and old

It's not perfect, but I'm more than happy with the result.

She's much better with a dash

It's taken so long getting the fiddly nights on behind, will have to be tomorrow to fit the vents

Well done - great result!

5/16 bolts inside binnacle x4
Bottom 2 can just be loose, top ones need to be removed, or in this case returned

A bit fiddly have to move around the whites a bit.
But it's possible to reach the bottom two to re tighten with an extension
So the troops looking lovely, but there's a little welding/fabrication needed for the bottom shelf/airbox and that's the next job


So it's off to the old railway line for a walk with the dog now

That dash repair is great. Gives me hope for when my time comes. Well done.

Thanks.
It was not possible to have completely flat foam due to its age I suppose, so there are some undulations to the finish.
However I'm very happy with the result and am making a dog ramp which will be covered in vynal too, for my fourteen year old Jack Russell.

The dog ramp, ready for vynal

There's a wooden hook which locks it in place

Dog ramp finished lol

My dog is fourteen, and it's nice for her to be able to get in and out

It stows quite easily too

Nice job. Hope the dog appreciates the work you put into it

Next part of the under dash needs some re-fabrication

It's a bit gone at the bottom

So I'm making card pattern to transfer to metal to replace what's been eaten by the tin worm, and to replace any badly corroded parts.
Most of its pretty solid though.

Finding some small holes while cleaning the black and red under coat off. Wonder if the base red is lead? I'm wearing a respirator anyway and swept up all the dust!!




This part is from the far left side

looking at the entire under dash.
Got new rubber seals from Britpart to replace the old melting ones
Made some card templates and found some 0.7mm galv steel.
The rubber seal fits fine, just hope I've got four.

Got a lovely separation between foam and metal of lower dash, the vynal is still bonded to the foam in one piece.

Which would be useful if just doing metal repair.

Continuing on with the restoration of the left most box section of the dash.

Made card patterns and cut out rotten metal, first part tracked on the bottom.

And with a lot of subtle fettling to the corner part its good to tack I will cut and weld the bottom flange separate to get a better finish

Still more getting to do, but it's coming together.

After welding up, and after some beating and slapping to correct slight distortions. Got a good fit to the original foam and try fit to car.

Just a small adjustment to the bottom hole to do and it fits well. It covers the windscreen wiper motor

It was rotten along the bottom, I assume from water leaking in, so I will put paint it with Raptor to help it resist the effects of sitting water.


no point in Worrying too much about finish as it's covered in thick foam

Nice job there! Looks factory fresh

Hopefully once covered it will look better, but it's got lots of protective paint
Inside too

Thing to attend to the main hollow heater/dash tray section.