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Rebuilding Rusted / Damaged Body


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7 replies to this topic

#1 Loyale 2.7 Turbo

Loyale 2.7 Turbo

    The Mighty "BumbleBeast"

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  • Roatán, Honduras.

Posted 13 October 2011 - 12:47 PM

My Loyale 2.7 had a certain Front end Damage that Wrecked the Engine, as you can Read here:

http://www.ultimatesubaru.org/forum/showthread.php?t=117604

But Since my Dad Removed the engine and repaired the engine's Bay in order to obtain a New engine; I Started to Work in a Deep Body Restoration of it.

First of all, the Previous owner of this Wagon had a Short Garage, so the Rear part was sticking outside.
So the Rainy weather Posted Image had rusted parts of it that I had repaired in the Past.

But Now, I Decided to Remove all the Paint and everything else to expose the Metal Sheet.


Posted Image




Posted Image



inside and outside, I removed Everything!



Posted Image



Surprise! ... I Discovered that the area around the Fuel Filler cap of the Car had a Minor Hit that Pushed one inch the Sheetmetal to the inside, and the Previous Owner, instead of Fixing that, covered the area with Bondo; and it was even Worse: There was Rust Hiding behind that! Posted Image



Posted Image



So I Used a Tool to Remove that Bondo:



Posted Image


Edited by subeman90, 22 February 2012 - 07:39 PM.


#2 Loyale 2.7 Turbo

Loyale 2.7 Turbo

    The Mighty "BumbleBeast"

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  • Roatán, Honduras.

Posted 13 October 2011 - 01:07 PM

I Removed Everything and this is how the Rust was:



Posted Image



it even went to the inside! Posted Image



Posted Image



So I ended Removing all the Damaged Metal Sheet from the Car:



Posted Image



Posted Image



Lookin' from the inside:



Posted Image



it even has some Rust on the Other Side:



Posted Image



inside Pic:



Posted Image




Edited by subeman90, 22 February 2012 - 07:40 PM.


#3 Loyale 2.7 Turbo

Loyale 2.7 Turbo

    The Mighty "BumbleBeast"

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Posted 13 October 2011 - 01:16 PM

I Obtained a Used Door from another car, its Metal Sheet was like New


and Looked like a Better Quality than the one on my Subie.



I Cutted the Metal Pieces from that Red Door, Molded their Shape and Tested How them fit:



Posted Image



and the Other Side:



Posted Image



Then the Welding Party Started: Posted Image



Posted Image



This is How it Looked like Just Welded:



Posted Image



Posted Image



After Deep Cleaning the Areas (inside & Outside)
I Started to Cover all the inside with a Premium Anti-Rust Product:



Posted Image



Posted Image



Posted Image



With Special Care to the Electric Stuff around:



Posted Image


(you can see the Relay Swap, explained here)


Edited by subeman90, 22 February 2012 - 07:40 PM.
add Link to the Relay Writeup


#4 Loyale 2.7 Turbo

Loyale 2.7 Turbo

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Posted 13 October 2011 - 01:26 PM


Time for Fine Sand Paper & Prepare the Whole Car for a New Finish:



Posted Image



Slowly started to Look Better:



Posted Image



Here, the Primer Coat was Applied:



Posted Image



Posted Image



Then Sanded Down and another Primer Coat applied:



Posted Image



The Other Side:



Posted Image



Posted Image


Edited by subeman90, 22 February 2012 - 07:41 PM.


#5 Loyale 2.7 Turbo

Loyale 2.7 Turbo

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Posted 13 October 2011 - 01:43 PM


The day was Rainy as you can see Mud Spills on the Primer, but it was Dried when Rain Started.

Edited by subeman90, 22 February 2012 - 07:41 PM.


#6 Loyale 2.7 Turbo

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Posted 13 October 2011 - 01:45 PM


Then I Purchased the Polyurethane Paint:


Posted Image


The Primer was also from the Same Brand.


Edited by subeman90, 22 February 2012 - 07:42 PM.


#7 Loyale 2.7 Turbo

Loyale 2.7 Turbo

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Posted 13 October 2011 - 01:50 PM

The Paint Party Started: Posted Image



Posted Image



Posted Image



Posted Image



Then, after more fine Sandpaper, came the Second Coat:



Posted Image


Edited by subeman90, 22 February 2012 - 07:42 PM.


#8 Loyale 2.7 Turbo

Loyale 2.7 Turbo

    The Mighty "BumbleBeast"

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Posted 13 October 2011 - 01:54 PM

The Body Restoration has Finished, I Washed Clean the Carpets and the Seats, even the Door Panels; I Just need free time to go another Weekend to my Hometown and Put it Back Together.

Now, I Just Need a New Engine for it ... Posted Image ...

Kind Regards.

Edited by subeman90, 22 February 2012 - 07:42 PM.





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