[crepello]

Quite an encouraging story, this. A welcome contrast to the usual stories (on FaceBook especially) of decent cars being taken on the opposite trajectory.

Did you basically drill out the existing spot welds and then plug weld at those locations on reassembly?

[Cthomas]

Nice to see you here James. I’ve watched the sd1 police car on Matt’s YouTube

Yes that was a result. He also did a road test of this car.

Was talking to Matt this morning about both drive tests.
He collected strut tops for the Alfa 145.
When are you getting back on the diesel sd1? Looking forward to seeing the manifold bits you got from me.
Are you still keeping the 420gsi?
I would love a 420gsi saloon again but a rover 216 vdp sd3 came up like I had in the 90’s

[N1tr0_9]

Quite an encouraging story, this. A welcome contrast to the usual stories (on FaceBook especially) of decent cars being taken on the opposite trajectory.

Did you basically drill out the existing spot welds and then plug weld at those locations on reassembly?

Yes drilled out the existing spot welds on the donor panel, the used a paint scraper and hammer to cut through to the final parts. Then plug welded back through this same holes. I did loads of videos showing the process. I’ll post a link. James

[N1tr0_9]

Nice to see you here James. I’ve watched the sd1 police car on Matt’s YouTube

Yes that was a result. He also did a road test of this car.

Was talking to Matt this morning about both drive tests.
He collected strut tops for the Alfa 145.
When are you getting back on the diesel sd1? Looking forward to seeing the manifold bits you got from me.
Are you still keeping the 420gsi?
I would love a 420gsi saloon again but a rover 216 vdp sd3 came up like I had in the 90’s

Small world. Not sure if I’m gonna use the manifold bits. There has been so much interest in that one I think I might just keep it all original.

Yes got to sell the 420gsi. I only took it on as I didn’t want to see it get broken up.

[N1tr0_9]

Picked up a genuine GSI bonnet with bulge for £60. Looks rough as a badger, because its been painted grey with badly shaken rattle cans, but it is completely rust free.

[N1tr0_9]

Fitted the coolant pipes

[N1tr0_9]

Spent an age prepping, degreasing, etch primering and then spraying green on parts of the slam panel. Ive just concentrated on the bits that will be hidden under the wings or generally a pain to get to. Hopefully the bodyshop will make it all look super pretty later.







https://www.youtube.com/watch?v=EbXfVFp0Eyo

[N1tr0_9]

Simon the previous owner provided me with a GSI spec front bumper which I'm chuffed with. It has the cut outs for front fog lights. This car never had them, but they look cool and easy enough to retrofit.



I took another look at the offside front wing, and the crusty bit. I made the decision that if I was gonna have the bonnet and bumper painted, I should also sort the rust. I was thinking about buying a wing, but when I unbolted this one its super solid at the bottom, just one nasty bit of grot. So I hacked it out and used a section out of a scrap wing from the bubble 200 to repair it. Welded it in and then bonda primer.

Rust out and new section trimmed.



Welded in and ground back



Primer



Then I refitted the rad and fan so its pretty much ready to be started up and taken to the body shop.

Rad in



Front bumper balanced on

[N1tr0_9]

Exciting news, car is now at the excellent Midland Performance and Retro to be painted. Its a bit of a trek for me, 400 miles round trip, but I know its in very safe hands with Mike and team.

All loaded up



Obligatory fuel stop photo



Arrived



2 days later, Christmas Eve, and Mike is already sending me photos!!!!!! Unbelievable work ethic. Thanks Mike.

Bonnet, wing, bumper, slam panel all being painted, as well as touching in some blemishes to the leading edge of roof and offside rear wing and lower edge of offside rear door.

Cant wait to get it back, hopefully end of Jan.

[N1tr0_9]

Got the 420gsi tourer back from the excellent MPR Midland Performance and Retro. Looks stunning. They painted both front wings, the bonnet, front bumper (including re texturing the black bits), the slam panel, front of roof, offside rear wing and offside rear door lower section. They then polished the whole car so it gleams!

They did a blinding job. Even the underside of the bonnet looks mint. The slam panel looks like its been polished smooth and so you would never know it had been repaired. Love it.

No i just have to put it all back together.

Ive ordered some new bolts for the headlamps and the plastic trims that hold the underbelly panel and arch liners so when they arrive ill get stuck in.





It was turning heads on the 200 mile journey home.





At home with the 827 stable mate



Underbonnet area