1993/K Classic 900 S Turbo Automatic restoration
September 2010: This is a customers car which is in good general condition but suffering from some bad localised corrosion, and a slipping auto gearbox.
The windscreen frame had very bad corrosion along the top edge. This was revealed when the owner asked Autoglass to replace the windscreen following a crack. Once removed the severity of the corrosion was revealed. The car was delivered to us initially to repair this and to diagnose the gearbox fault.
The corroded windscreen upper frame was completely cut out and fresh metal welded in and sealed, followed by the fitment of the new windscreen. Unfortunately we do not have photos of that part of the restoration. Initially the customer was then going to take the car away and think about a wider ranging restoration at a later date. However he then decided to have the rest of the work completed before collecting the car.
The agreed schedule of works is as follows:
Remove engine/gearbox and all engine bay components. Remove exterior trim. Grit blast engine bay. Repair bodywork as required. Respray bodywork and engine bay. Dinitrol aniti-corrosion treatment. Fit colour matched Carlsson Airflow body kit. Fit replacement gearbox and engine. Fit new (blue) hood.
The windscreen frame had very bad corrosion along the top edge. This was revealed when the owner asked Autoglass to replace the windscreen following a crack. Once removed the severity of the corrosion was revealed. The car was delivered to us initially to repair this and to diagnose the gearbox fault.
The corroded windscreen upper frame was completely cut out and fresh metal welded in and sealed, followed by the fitment of the new windscreen. Unfortunately we do not have photos of that part of the restoration. Initially the customer was then going to take the car away and think about a wider ranging restoration at a later date. However he then decided to have the rest of the work completed before collecting the car.
The agreed schedule of works is as follows:
Remove engine/gearbox and all engine bay components. Remove exterior trim. Grit blast engine bay. Repair bodywork as required. Respray bodywork and engine bay. Dinitrol aniti-corrosion treatment. Fit colour matched Carlsson Airflow body kit. Fit replacement gearbox and engine. Fit new (blue) hood.
October 2010:
Pictures of the car after engine/gearbox removal:
Pictures of the car after engine/gearbox removal:
 Above: Nearside of car following engine removal
 Above: Offside rear view of car
 Above: bad corrosion also found in O/S chassis rail behind bumper mounting.
 Above: close up picture of O/S rust
 Above: O/S inner engine bay lower section, some minor corrosion but generally sound.
 Above: O/S inner wing front section, some corrosion around the seams.
|  Above: Offside rear view of car
 Above: bad corrosion found in N/S chassis rail behind bumper mounting.
 Above: close up picture of N/S rust
 Above: N/S inner engine bay lower section, generally appears to be in good solid condition.
 Above: N/S inner wing front section, looks to be in good condition.
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Pictures of the car outside the bodyshop before work starts. Most exterior trim is removed, the final parts will be removed as/when required.
 Above: O/S front view of car
 Above: O/S rear wing. Structurally sound but loads of micro dents
 Above: Rear section. No major problems here
 Above: N/S front wing - again the wheel arch is in very good solid condition.
 Above: corrosion showing in N/S B-pillar
 Above: O/S inner door. corrosion along lower edge and corners.
 Above: close up of O/S door front corner
|  Above: O/S front wing - the wheel arch is in very good solid condition.
 Above: N/S rear wing. basically sound but some corrosion on the rear lower edge.
 Above: N/S door outer skin. lots of micro dents
 Above: O/S door outer skin. again lots of micro dents
 Above: corrosion showing in O/S B-pillar
 Above: N/S inner door. Again corroded along lower edge and corners.
 Above: close up of O/S door rear corner
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WARNING - PAST BODGE FOUND!
When attempting to discover the extent of the corrosion in the door bottoms, it was discovered that almost the entire length of both door bottom inner edges was filled with a mixture of mesh, filler, resin and underseal !!!
 Above: a small section showing the outer edge.
|  Above: the inner edge of the same section.
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November 2010:
Doors removed and all corrosion cut out. The following pictures show fresh metal welded in. Note the pictures are taken as a work in progress and show the metal before final finishing!
Doors removed and all corrosion cut out. The following pictures show fresh metal welded in. Note the pictures are taken as a work in progress and show the metal before final finishing!
 Above: Fresh metal in the O/S door
 Above: O/S door with corroded areas in base cut out and fresh meatl let in.
|  Above: Fresh metal in the N/S door
 Above: close up of N/S door rear corner
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Front section of engine bay following grit blasting. This enables all corroded areas to be revealed. Any corroded sections cut out and fresh metal welded in.
 Above: O/S inner section of engine bay
 Above: O/S Inner wing front sections - note photo taken before metal work completed
 Above: N/S chassis rail with corrosion cut out and fresh metal welded in
|  Above: View of front cross member and chassis rails.
 Above: N/S inner wing front sections
 Above: O/S chassis rail with corrosion cut out and fresh metal welded in
 Above: N/S lower engine bay
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Corrosion found in N/S rear wheel arch rear corner
 corrosion in lower seam as well as outer edge.
|  Same corroded area - Inner boot seam side
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Engine bay metalwork repaired and repainted, replacement powder coated slam panel fitted. exterior bodywork repairs continuing (hence the dust!) - click the pictures to enlarge:
Carlsson bodykit after priming and before final top coats:
December 2010:
Collecting car from bodyshop:
Collecting car from bodyshop:
Some close up pictures of panels, taken whilst still on transporter outside our workshop:
Car back from the bodyshop. Next job is to fit engine/gearbox unit and all enginebay components:
March 2011 - final pictures
