Vauxhall Cavalier Mk3 - Structural Repairs

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Fri 26 Jul 2013 12:06
Vauxhall Cavalier Mk3 - Structural Repairs - SteveGrove

Does anyone have any knowledge and/or experience of the viability of satisfactory welding repairs on a 1993 Cavalier.

I have such a car, but rather than scrap it, as it appears in basically sound condition, I was contemplating restoring it to nearer its former glory. However, before I spend much time on it, I need to know the feasability of welding repairs should I discover the need for any.

What parts can, or cannot be welded using conventional equipment? Which areas require specialist services and what equipment is needed?

Any advice on this would be greatfully recieved.

Thanks.

Steve.

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Fri 26 Jul 2013 14:02
Vauxhall Cavalier Mk3 - Structural Repairs - madf

Everything can be welded. Finding metal to weld it to may lead to replacement of badly corroded parts such as:

sills

Inner sills/inner wings/cross members etc

suspension mountings

Fuel tank

etc etc.

The costs involved - if there is extensive corrosion - will far exceed the economic value of the car..And given some are safty related - eg suspension - you need competent body shops with alignment tooling.

Depends how bad the corrosion is. Think possibly £1000ssss And then the car will with MOT be worth at best £500.

Edited by madf on 26/07/2013 at 14:03

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Fri 26 Jul 2013 15:26
Vauxhall Cavalier Mk3 - Structural Repairs - Andrew-T

Everything can be welded. Finding metal to weld it to may lead to replacement of badly corroded parts such as:

Fuel tank ... etc etc.

Fuel tank? Was it metal? Pugs had moved onto plastic ones way before 1993.

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Sat 27 Jul 2013 20:20
Vauxhall Cavalier Mk3 - Structural Repairs - SteveGrove

Thank you for your reply.

The car is basically sound with only surface rust except in a couple of small places.

The car belongs to my son who is loathe to get rid of it although it has been off the road for 3 years.

I know that it will be another 20 years before it is rare enough to be worth anything, but he and I can sort it out, between us, a bit at a time, and end up having a car to drive that we both like.

Regards,

Steve.

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Sat 27 Jul 2013 23:13
Vauxhall Cavalier Mk3 - Structural Repairs - Big John

Re "only surface rust except in a couple of small places"

The Bad news ---- Usually much worse than expected when you start cutting/wire brushing back to good metal

The good news ---- The Cavalier is made out of conventional steel that is easy (ish to weld)

You need a reasonable range of tools, starter for 10:-

1)A gas MIG welder/small hammer (+ mask)

2) Two small angle grinders are best. the first with a cutting disc and the second with a wire brush (you need to inter change a lot)

3) Drill and pop riviet gun to initially secure and earth some panelsbefore welding

4) High quality tin snips and a hack saw

5) A step Joddler can be useful (puts a slight step into steel)

6) Wood and dowels - useful making up positional jigs which may be required to mark the positions of body work before it is cut ot to give you a reference point for when you put it back. ( I once didn't do this on a Morris 1000 and had to find another good one to make up a jig to denote sill positions)

It is very satifying to see a rotten section of car body be restored. I remember worrying as I cut out what seemed like half the car (it wasn't) to then be impressed when a few minutes later I could jack the car up on the new bodywork.

Rust proffing is also very important after completion as the welding process can leave metal very prone to further rapid rusting. If you get this right then it will outlive the original - I recentley saw a 1967 Morris 1000 I restored for someone in 1988 where I had already got the hang of rustproofing. All the partsI had rebuilt were still tacky with rustproofing - the only parts starting to go were area that were still in good condition at the time - e.g. boot lid.

Beware fire(you don't always see it through a welding mask). Its easy to set fire to all sorts - fuel, brake fluid, oil, carpet, sound proofing, seat padding, headlining etc.......

Go for it - you may even enjoy it - and what have you got to loose.If you fail you will send it to the scrap yard - if you don't do it you will also send it to the scrap yard! I started with a Vauxhall Viva a few decades ago.

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