1994 Cavalier LSi C20NE (was C18NZ) Work-horse

[Robsey]

Got a new present from Klokkerholm in Denmark or Holland... not sure which.
Sadly I ordered a matching pair, but they forgot to send the passenger side (left hand) panel.

So here is the driver's (right hand) side chassis rail.










I have also ordered a rear cross member...from genuinepartssearch.
So hopefully get that on Monday.

[Super89]

Well sorted! Will last you another 20 years easy after this work.

[Robsey]

That is the plan - a fully sorted body and chassis that will last for a lot more years.

[C20letlad]

Well over the past few days ive gone through this thread from start to finish and i am amazed at the work that has gone into this cav ! The welding is fantastic and seeing it come together is great i would love to see the mot guys face once its done im sure he will ask if its the same car !

[Envoy CDX]

Very nice, though thats only part of it from the looks of it Rob.

[Robsey]

Yes, I bet Dave will be pleased with what he sees.

He won't be mega surprised though, because he half expects me to keep taking it back for the next twenty years.

And I did say that I would be getting a welding expert in, who is also a huge Cavalier fan.

Just looking forward to seeing the old girl when she is finished in a couple of months.

Yep - Gary...
Troy does have his work cut out for him... driver's side sills and arch should be sorted now.

Chassis rails, rear valance, rear cross member and then the passenger side sills to do.

I presume the rear passenger side belt location will need to be replaced too.
That bolt looks totally rusted in place.

Amazingly I read it last night too.
Sad to think that I have been threatening to do the welding for about 4 or 5 years... eek!!

[Envoy CDX]

Aye, it'll get there though

[Robsey]

Another piece for Troy to play with.

Rear cross member delivered from a dealer in Liverpool.
It was a bit bent when it arrived just wrapped in an oversize plastic bag

[Robsey]

Some more progress - driver's side boot floor...
More Troy magic...

Before - oops rusty hole..



Rust cut out..



And new shiny fresh metal.
Complete with strengthening rib




Wait 'til you see the state of my rear valance - eeek!!

[TurboDan]

Great work as usual troy!

Your cav is in good hands robsey

[Robsey]

The very poorly valance...
Or lack of valance -

Valance cut away to access the rear cross member.
The cross member is nothing but a layer of "flakey pastry".

[Robsey]

Great work as usual troy!

Your cav is in good hands robsey

Indeed - it is awesome to see the work in the metal.
I could spend all evening watching Troy performing his magic, but he'd get bugger all done if I keep disturbing him.

So I drop in from time to time to drop off panels or biscuits.

it will be both next time Troy... biscuits and left hand chassis rail.

[btcctroy]

The rear valence doesn't look like that anymore :)

[James McGrath]

Looking good!

Always a pleasure to see a restoration like this.

[Robsey]

I am keen to point out that Troy is the good guy here...

I have not done anything to restore this car, except provide a few body panels of mixed quality, half a dozen packets of biscuits, an angel cake and some money towards his materials and his time.

If this was a pantomime, then the name Robsey would be followed by resounding echoes of boos and hisses for letting the Cav get this bad.

On the up side - If my car can be restored, then so can anybody else's - depending upon how much you want it done and how much you are willing to pay...

[Lowrider Dave]

Great to see progress, Troy's work looks top notch. Most envious!

[Robsey]

Great to see progress, Troy's work looks top notch. Most envious!

Indeed - His eye for detail is amazing.
Right down to reinforcing webs and punch-formed holes just as GM intended, even though they are not visible when all the panels are in place.

[Robsey]

The valance is done...

Looks like it had never been rotten.







This is one restoration that Troy won't forget - simply due to the amount of work required.
I am sure my car IS certifiably the most rotted ever.

Yikes.

[btcctroy]

Not the worst I have seen.
It holds the record for the worst I've had to repair
Will be a very nice restored cavalier when it's finished. Robsey will no doubt hit the 500,000mile barrier, his cars are the opposite to ornaments

[Robsey]

Indeed -
As soon as the old girl is finished, MOT'd and taxed, she will be churning out the miles along the entire lengths of the M53, M56 and M60 motorways.

Although I will be looking after her a lot better than her previous "work horse" life style.

[Envoy CDX]

Very cool nice to see it coming together Robsey / Troy.

[Robsey]

More of that wonder welding.

I used to have a "Towsure" tow bar fitted.
However the wheel well was left pretty much peppered with holes and rust.
So it was agreed to get rid of the tow bar...
even though it worked a treat at protecting the old girl from rear end shunts.

Before - From underneath...




After - from inside the hatch...

[Envoy CDX]

Turned out better than I thought it was going to when you mentioned being peppered with holes.
I'd imagine parts of it were rather thin.

[Robsey]

Aye Gary,

But you know as well as I do,
photos can sometimes make a rough piece of body work look better than it is in the metal.

Pity I didn't have a before picture of the inside of the wheel well. That corrosion was very deep and crusty.

Looking sweet now though.

Last of my new parts arrived yesterday.
Left / Near / passenger side chassis leg.
Woo hoo!!

[Envoy CDX]

Excellent stuff