Goce Posted May 15, 2023 Author Report Share Posted May 15, 2023 Hmm, i'm suprase there are no holes in the roof skin, the roof rails bolt thru down to the roof structure. Quote Link to comment Share on other sites More sharing options...
Goce Posted May 16, 2023 Author Report Share Posted May 16, 2023 Today i had the day off work, so i spent a lot of it taking apart this car. I'll be changing the color so i need to take almost everything out. I took it down to bare shell, only the front carpet had to stay, it hold up under the dashboard. I found some unexpended rust under the back seat. My spare room i now full of car parts. I have lots of sanding to get all the door jams, the inner panels are much different then the 405 and i'm seeing some holes for speakers that i may have to install. Quote Link to comment Share on other sites More sharing options...
Goce Posted May 19, 2023 Author Report Share Posted May 19, 2023 Today i spent some time with my pressure washer, degreaser and a bunch of brashses, washed all the doors inside and in between. I did get some water on the dash. I also found those german 50 pfennig, one 1950 other 1976, this car has been imported from germany, i'm not sure if those have any value. Quote Link to comment Share on other sites More sharing options...
Goce Posted May 23, 2023 Author Report Share Posted May 23, 2023 Today i started on the body work on this project, first i started with some bubbling paint in the trunk jam. I sanded  down the entire trunk and jams, then i removed the rear bumper, took off the trim and welded couple of the cracks it had, then i washed it, there was about 5kg of mud inside it. Quote Link to comment Share on other sites More sharing options...
Goce Posted May 26, 2023 Author Report Share Posted May 26, 2023 I continue with the body work, the trunk has a dent that i hammer out, then used 2 layers of body filler to fix, i actually measured the body filler and its less than 0,5 mm. After that i continued with sending what was left of the clear coat on the doors and the roof, i hate body work but if i want it done right i'll have to do it myself. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 6, 2023 Author Report Share Posted June 6, 2023 I continue working on this car, today i dealt with all the rust on the surfaces. The hood had lots of stone chips, the rear arches has some as well. Then i started doing the body work in the passenger side doors. The door dings got filled and all the clear coat got sanded because it was starting to bubble. I'm using 3 different body fillers depended on the spot. The rocker panel is a real mess i glue couple of studs to try pulling the dents the big dent is going to require welding for sure. Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 6, 2023 Report Share Posted June 6, 2023 Really nice work! Quote Link to comment Share on other sites More sharing options...
Goce Posted June 8, 2023 Author Report Share Posted June 8, 2023 Today i spent a lot of time filling dents on the doors, hood and arches. That second part of my day i welded pieces of metal to the dented rocker panel, used my pull hammer to pull the rocker out. I left the back one so i can attach my grand cable. The rocker panel seems to have been repaired before with lead it's very rusted at the bottom, and pulling it made more holes. I'll probably end up just replace the entire panel. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 11, 2023 Author Report Share Posted June 11, 2023 Today was a very long hard and stinky day in the big garage, i prepared and undercoated under all 4 wheels, front subframe and the inside of the front wings. I use black stone chip with a special paint gun and apply about 3 kg of that staff all surfaces got 3-5mm thick coat except the front wings the inner fenders won't fit if i got too thick. This product is to protect from rust and good sound and vibration insulation. This car being a 4 series is not as good insulated as higher end models. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 16, 2023 Author Report Share Posted June 16, 2023 Next on the list to fix is the rocker panel. After pulling the dents out and cutting out the rust there was not much left. Looking at my options i decided if i want it to last i need to replace it entire. So couple of phone calls later i bought a new rocker panel, it is galvanized, from what i found out is the best quality available, it was 45$ not too expensive. Now the hard part, replacing it. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 17, 2023 Author Report Share Posted June 17, 2023 Today i started on roker replacement, I put the new panel on top of the old and marked the edges. I'll put about 10 mm overlap do after removing the new panel i got cutting. I did this job on top of jack stands for easier access, but after this i'll put it on the ground for a exact fit. There is lots of surface rust, which i clean off then spray anti rust acid, because of that it looks so dark. For removing the spot welds i use my finger sander with P40 paper and sand off the old spot welds. I'll leave the acid to do its job overnight, tomorrow i'll weld up the holes and apply primer before welding the new panel. It was a hard and dirty day in the garage, and i somehow got a piece of metal in my eye. Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 18, 2023 Report Share Posted June 18, 2023 Damn, get that eye checked out in a hospital or clinic. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 19, 2023 Author Report Share Posted June 19, 2023 I did go to the hospital, they dig out piece of car color and metal, in total they found 5 pieces. With that eye shut tight i got to welding up some of the holes, i also welded up the hole under the back seat and apply some high zinc etching primer on all the surfaces including the inside of the new roker panel, also i'm looking for cavity wax to protect it on the inside. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 20, 2023 Author Report Share Posted June 20, 2023 Today was a long day first at work then i stop by and bought cavity wax and a 60 sm application hose. It was hard to find and expensive. Then i prep the new rocker panel and welded it. This was the easy part, grinding back the welds took twice longer. After the grinding i spray the welds with anti rust acid to get rid of any rust oxidation. Then i try the wax on the inside of the rocker panel and on the front wings. I'm planning to keep this car longer so i'm taking all the preventions. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 26, 2023 Author Report Share Posted June 26, 2023 Today i continue with the body work, i fited the new front bumper to take shape. Had to adjust the front fenders, the dented passenger fender will need a bit more filling than i like to use so to give it fighting chance i bought and used fiberglass reinforced body filler. That body fiber is hard staff to use but seems to adhere much stronger, i did ruin two spreaders. Fixing that front fender i did take and install the front bumper about 5 times. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 28, 2023 Author Report Share Posted June 28, 2023 After few days of block sanding the trunk, roof and hood are ready for primer. This time i'm using 2K primer that supposed to be very good quality, it was expensive. I also prime the front wings, the passenger one needs a bit more work but i'll do it after. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 29, 2023 Author Report Share Posted June 29, 2023 Today i did a lot more sanding and priming. All the small parts took me lot of time but i managed to finish both sides and all the smaller parts. Quote Link to comment Share on other sites More sharing options...
Goce Posted July 1, 2023 Author Report Share Posted July 1, 2023 Today i spent my free time working on this car. The rocker panels needed some work, drivers side had couple dents that i fill and then apply stone chip (white). Passenger side also got stone chip from inside and out, i also used the entire bottle on the frame and some of the back panels where mud collects. You may noticed i've moved it to the small garage and i've found couple more dents that need to be repair. Quote Link to comment Share on other sites More sharing options...
Goce Posted July 3, 2023 Author Report Share Posted July 3, 2023 Last few days i've been sunbathing this car, so the primer can cure and shrink in. After that i took a black spray paint and painted lines to use as guide coat, now it looks like a zebra. I also started working on some of the dents i've found, the lighter color primer is what i had left from previous project so i used it. Its coming alone i hope to have it prep and painted before the summer heat comes. Quote Link to comment Share on other sites More sharing options...
Goce Posted July 8, 2023 Author Report Share Posted July 8, 2023 I've been working on this car every time i have free time, the primer i used is very hard to sand. Also i did a bit more repairs on the back bumper. The roof will be very hard to sand smooth. Quote Link to comment Share on other sites More sharing options...
Goce Posted July 10, 2023 Author Report Share Posted July 10, 2023 Today was a long day, i went to buy parts for this project but come home with an entire car. This 406 sedan is a macedonian car from new, as you can see it has only 120k on the clock. But the front wings, rear arches are rusted thru because no one here washes the mud. That doesn't concern me because the body shell will go to scrapyard. The engine is not good, from what the previous owner told me a gas station attendant fill it with gasoline instead of diesel. The car started to drive more responsive and after about 100 km started to smoke and make noise, took it to a service garage. They diagnose it that it has bad turbocharger, the owner bought a new turbo charger, they replaced it and it was still the same. After that he had i towed to his home, there he called a mechanic there they unscrod the fuel injectors and seen the fuel coming smell more like gasoline. The car now has all 4 injectors out, i'm not planning to mess with this engine now. The older guy gave me another set of summer tires, battery is new, also the turbocharger on the engine is supposed to be new. I need to take apart this car and get it stored for spares. So i can get back to standing on the wagon, that primer is hard as a rock. Quote Link to comment Share on other sites More sharing options...
Goce Posted July 13, 2023 Author Report Share Posted July 13, 2023 Last few days i've taken this parts car apart, If i had the space i'll left it whole but i don't have where to park it. Bit by bit it come apart easy, the hardest part was cutting it apart. I'll have spare parts for years to come. Now i can get back to standing on the wagon. Quote Link to comment Share on other sites More sharing options...
Goce Posted July 14, 2023 Author Report Share Posted July 14, 2023 With a full day of sanding i managed to get this project to the point where i'm calling it done, ready for paint, i washed it off and made an appointment for the paint booth. I'll have to choose a color, i'm looking a peugeot's EKB. Quote Link to comment Share on other sites More sharing options...
Goce Posted July 16, 2023 Author Report Share Posted July 16, 2023 Yesterday i bought paint supplies for this car, men have the prices rise. And today i drove the car to the paint booth, there i spent some time masking it and hopefully in few days i'll have a red 406. For the color i chosen body's ral 3020 it's the closest to peugeo's red color also is called traffic red. Quote Link to comment Share on other sites More sharing options...
Goce Posted July 17, 2023 Author Report Share Posted July 17, 2023 Today i got the call, i'm out of paint. So i went bought some more and took it there, went back to work. Few hours later got a second call, it's done. Went there, unmasked it, attached the bumpers and drove it 2-30 km home. The color is on point, not to bright, not too dark, it has few dry spots and couple of runs but for a daily driver is more then good. Next on the list is to remove the dashboard and front carpet. Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.