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August 2, 2023

Rust Diaries, Day 13: From big to samll

The next logical step was to tidy up all the remaining small parts, and that’s exactly what we did. Quite a few of them went through zinc plating.

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July 30, 2023

Rust Diaries, Day 12: Subframes

During the break from the sheet metal on the underside, we tackled the bigger parts: subframe, trailing arms, differential and driveshaft mounts, sway bar — basically everything we could get our hands on. The only difference was that all those parts went straight into sandblasting. As the car had only 56,000 km on it, the bushings were in very good shape, so we decided against powder coating the parts with the bushings, as it would ruin them in the process–for those it was the usual treatment Dinitrol and Interplus. There’s something to be said about those OEM parts — sure, you could replace them with the likes of Powerflex, but that didn’t feel right. Everything else was powder coated, though.

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July 26, 2023

Rust Diaries, Days of abrasion

The first grinding sessions quickly turned into worn-out discs, bald brushes, and soot-covered faces. The days blended into a blurred continuity, punctuated by Dinitrol and Interplus 256. Our best friends became the angle grinder and the power drill. For the most stubborn areas, we resorted to sand blasting, but that was definitely the minority.

I like this picture quite a lot; it shows the stages nicely: in the middle, bare metal; to the right, covered with Dinitrol RC 900 – rust converted and primer; and finally, on the far right (ahem), still untouched.

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July 24, 2023

The Goodies

In the meantime, the goodies:

Oil pressure and temperature, as well as turbo boost from Defi, in the ATI gauge pod. That pod was really hard to find; I tracked it down in the Netherlands.

For completeness, the console, all the sensors and the wiring:

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July 19, 2023

Rust Diaries, Days 4 and 5: Brushes

Some conceptual work, preparation for cleaning, and testing of various wire brushes and polyamide abrasive discs were done.

The car’s body was wrapped to protect the paintwork and then moved under the shelter.

We also managed to disassemble the rear axle.

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July 17, 2023

Rust Diaries, Day 3: Rear suspension and fuel tank

It’s warm, so the car is melting quickly. Today, we dismantled the entire rear suspension: struts, springs, brakes, axles with the differential, the fuel tank, and the rear crossmember. The work is going surprisingly well; Tomek’s dad is well skilled.

On the downside, we snapped two bolts — one from the diff mounting and one from the rear suspension trailing arm. There’s a nearby access hole, but we don’t have much hope for success.

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July 15, 2023

Rust Diaries, Day 2: Turntable mounts and gearbox

Whit the chassis frame entry points in sight it was now time to attach the mounts. As described in a previous post the front required angle brackets welded in, which attach to the frame with two bolts and slide in to the turntable nicely:

The back fits just as snugly, utilizing the bolt holes originally present on the frame:

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July 14, 2023

Rust Diaries, Day 1: The starting point

Goal for today: main chassis frame. We don’t have a garage lift (at least not yet), so the plan is to do all the work using a paint-shop-style turntable. This will give us good up-and-down movement, and when we need to strip the underside, we should be able to tilt the car sideways easily. The inserts for the chassis frame will be made from 50x50mm thick-walled profiles (which fit perfectly into the internal profile of the turntable mount). At the rear, there will be 3 bolts on each side, directly into the frame rails. At the front, an angle iron will be welded to the profile, with 2 bolts on each side, going into the beam mounting holes.

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July 13, 2023

Rust Diaries, Day 0: Nowy Sącz

Alarm set for 5 a.m., quick coffee, and off we go. Of course, via Jasło and Gorlice, not the A4 — never miss a chance to take a few more corners. By 8:04, we’re at the workshop: Tomek in a tow truck from a friend, and me in the Impreza. Rendezvous back at 12. By 12:58, this is the view:

It will be a good few weeks before that EJ257 will be reunited with the rest of the car.

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