Rover P4: N/S body Repairs Cutting out the Rot

[@PhilRiley-v9n]

I believe the access panel was to allow access for the 1950s spot welder to get inside that section to do its work.

[@jesscourt9068]

What you are doing by dissecting the repairs is the easiest and correct way to do this in my opinion. You eventually will be able to see the correct construction, and repair/remake so that the panels will fit and support. I eventually got myself an air hacksaw, which became my go to tool, as you can remove rust with it by using old blades to vibrate and clean, plus i cut much straighter lines with it. Cutting discs are great until the space is restricted. You will need a minimum CFM of 4/5 with your compressor though, but if you use air tools you will have that anyway. Good video.

[@davidbaugh]

Thanks. I may need to replace a small section of the floor too. I'm trying to approach doing these repairs in a logical way, I may be being a little too cautious.....all a learning curve. I almost bought a reciprocating saw a few months ago but see one will bee essential.

[@russthebiker]

I wonder how many other nice looking classic cars are hiding bodgery like this ? Its a long old job ripping it all out, but it will be a strong and safe car when you are finished I bought a hot air gun from machine mart, its great for softening sealants , seized nuts and bolts and underseal I managed to get an origional factory parts book forvmy car, it has exploded diagrams of the entire body shell, very useful when making repair panels, and trying to undo previous repairs where old weld line's and seams are obscured

[@davidbaugh]

I think a fair few are hiding surprises. I know I've said it a few times, but this car had a lot of money spent on it in the early to late 2000's and the standard of the work is does not match the money paid. The standard of welding is atrocious. A hot air gun is on my list of tools to get, first I need a reciprocating saw.. I have a parts manual too, I agree they are essential.

[@russthebiker]

@@davidbaugh I scanned mine and them stopped sections enlarged to A4 then laminated them Can't cope with technology very well I stapled them along the workshop wall, and also some images of origional cars taken from below I work better with pictures!!!just building a tardis that way

[@redfoxclassics]

Ugh, I think I said before but undoing nasty old repairs really is the worst! I think you’re going about it in a sensible way. If you find you need to cut away good original panels to gain access to other rotten sections then my suggestion would be to either make sure you can save them, or build the replacement before you cut in order to not lose any info. Strongly recommended covering up your glass and interior too. I ruined a door glass on my Spitfire with grinding sparks and was most annoyed. The bit you’re calling an access panel, I assume it would originally have been screwed in place or similar? Otherwise it wouldn’t let you access anything… Presumably it was for getting to that inner hinge bolt?

[@davidbaugh]

Thanks. I remember getting some weld spatter on a Spitfire windscreen many years ago..thanks for the reminder.. I don't know why it's called an access panel, someone has commented it's for access to spot weld.....I have never seen one screwed in place only welded.. It doesn't hinder getting to the Hinge Bolts..

[@rubbishsignup]

When Time Team meets rover p4 rust😢