Vauxhall Cavalier Mk3 Owners Club - cavmk3oc

after finding out that my cav has been quietly rusting without my knowledge , today i started the work on replacing the floor pan .

heres what i found the other day



so today after lots of poking and grinding, its back to clean metal and a quick rust teatment and some primer heres the result



I contacted chip foose to see if he was interested ... but wasn't so made my own template



the joint will be butt welded and smoothed of (just like a pro) and the fold im not sure with just yet , i know once the seam sealer is re-applied it wont be seen ,but for now the plan is repair the floor, take the bumper off and repair the back edge ,welding to 2 together , to crate a fine piece of art , worthy of any gallery


P S ... Im not happy about it as its the first time a welder has needed to be took to it , I feel let down by my cav , the bitch has done the sly on me , boo! hoo!

good to see youre getting to grips with it, chip would be proud


"i'm proud of you branny. now, make it look like this"

Good luck with it, personally, any sealer that is remotely "brown" I'd be knocking out to see whats lurking behind
It'll be good to see the progress.

lovin the foose pic really tickled me

reminds me of mine lol. a section out of a scraped cav would be the nicest finished but think urs is a gsi, so harder to come by.

if it was a normal cav saloon id cut you one out so it looked stock

Hatchback with a modified GSi kit Troy

quickest and best finish would be from an cav in my opinion

generally makes no odds but i like the finish to look like its never been touched.

i could get you that section if you want.

thanks but i will make it up by hand , and hopefully it should look good as original , i'm off next week so if the weather is kind , a couple of days work should put it right

How are you getting on with this Branny?

Well...... gets the mig out after cutting my steel out of the template , fitted it in and sparked up the welder, started to get a few small tacks to keep it in place then the bloody machine ran out of wire ordered some on sunday (900g for 12 quid ) got an email today saying its been dispatched under std delivery so hoping to get it in the next few days , and get the job finished , i will take some more pics as i go





may sell after the next mot (pissed off its needed welding so dont want it now)

Can't be helped if it needs welding, but it's not a huge amount of work it's required? What will you replace it with?

correct answer: another cavalier

shame, i rather like yours, its a nice motor

it is a shame but thats the only rot on it .

well .... lads got me wire this morning so off we go , more piccies for yeah

also noticed it has been weeping through some pinholes on the turret ,so promply give it the grinder and a new piece of pre-galv steel ,



and just like a pro some "bondo" on the welds to smooth things in , and a lick of paint ...





from under the arch


next up the boot floor


welded the seam and ground it flush followed by a skim of filler .




now ive stiched it to the inner wheel arch but the bumper needs to come off to do the exterior work

looking from under I have seam sealed the joint , which will be followed by a load of paint ,then the final underseal




also joined up the inner lip ,



last up the external lower quarter has a small hole in it ,this will be made up alng with the outer lip and welded together , thats tomorrows job.

then its the same on the other side although its not half as bad .

Once its all done I may give the whole boot a coat of magic grey to finish it off and bring the whole job together

Looks good Branny, I will say this though, top of the arch where it's a bit crusty on the lip, get your head up inside the rear arch and look for damaged underseal thats how my previous cav died

I will do ... after finding what i have , it will be getting a full overhaul on the back end before the winter sets in

good man

finished off the drivers side today , plated the lower quarter, and leveled with some filler then seam sealed it ,
along with the small piece of lip that was missing in the wheel arch



got some weld on the inside of the outer plate ,to add to the stiffness



undersealed and a dash of primer and paint although the colour is piss weak as i need some more magic grey to complete the whole boot when ive finished the other side

All good progress

how are you getting on with this?

haven quite finished it yet gary? (is it) done the other side of the floor i and drilled the drain holes in and refitted the pipes it , so the boot floor is watertight again plus being back at work and the weather a bit iffy i havent bothered for a couple of weeks and as you know i was a bit involved in getting the belmont going .
I only need to pull the bumper and repair the lower outer side of the quater panel and buy some more paint and its done .

I will get a final picture up on the thread as soon as its done

Yeah, tis Gary
No worries, just curious as to how you were progressing with it