Mikey's 1992 Range Rover Vogue 3.9

[mikey]

I just bought this. It's got "some rust", but it's not terrible ... I think. Pretty much every interior panel is broken and most switches don't work. It's lovely to drive, even thou it's a bit knackered it still feels fancy. 

My plans are to sort the rust out, DIY respray, fix all the broken things and enjoy it. 

 

 

Discuss here

[mikey]

I love a build thread full of rust repairs, so satisfying. But not something I want to spend my weekend doing...

Oh well... I attacked what I thought was the worst. Years of wet carpet has caused this.

 

The sill was sweet inside, lots of wax in there. 

 

I removed the rear seats to find this....

 

Eeeeep.

 

At least the bottom of the tailgate is mint.

 

The top is fucko'd...

 

It really could be better / worse

[mikey]

Did some CAD. Happy days!

This gap looks quite big, but it pulled away when I cut this panel, so attempting to put in the same gap.

 

 

[mikey]

I had a poke around at the passenger B-pillar. Yikes!

 

 

 

 

These are the last bad bits of rust done. I had a peek under the car and was amazed at how mint it all was, seems like most of the rust was caused by wet carpets and the rest of the body is good. 

I'm not totally chuffed with that b-pillar repair, it's solid, but could be tidier. The rest I'm happy with. 

 

 

 

[mikey]

One. Two. Miss a few. 99. Paint!

Came out good enough. Satin black for the pillars. PPG 2K epoxy primer, seam sealed & Deltron single stage.

The previous repairs stand out quite a bit. 

There's a bit of dust in these photos from removing the masking.

 

 

 

 

[mikey]

Hmmm, pretty crusty under the scuttle panel... This patch was brazed over the worst of it. 

 

 

 

 

 

 

I had to make the repair in two sections as there was too many curves for my lack of skillz

 

I cut the middle section under the scuttle out too, but is was okay so welded it back in. I've got a similar but smaller repair to make on the passenger side.  

[mikey]

Similar state on the passenger side.

 

Epoxy primer and seam sealer. Hopefully no more leaks!

I learnt you shouldn't feather seam sealer edges because it will pucker up when painted over.

 

I treated a load of light surface rust around the engine bay & under the radiator supports. Repainted everything. Stoked to have the rust repairs complete!

Now it's time to start putting things back together and start on the exterior. 

 

[mikey]

Minor update, put all the engine bay back together. Replaced the knackered fan resistor.

 

Starting prepping the roof, fenders & quarters for paint:

 

[mikey]

Heartbreaking few days in the garage. My wife was away for the long weekend, so made a goal of having the shell painted - roof, rear quarters and guards. Worked 3 days solid. All started pretty well:

Skim & block:

 

Highbuild:

 

Sand to 400 grit. Everything was nice and flat

 

Then I put colour down. The roof was okay, a bit dusty, but what I'd expect for a garage job. 

But holy fuck balls, everything else was orange peel and runs. This is probably the worst panel. 

I know I've fucked up the mix or gun settings. I'll have to sand it and do it again. But right now I can't bare to look at it. 

 

Caaaaarnts.

 

[mikey]

Progress  I've finished painting the fenders and I've redone the pillars in matt black. Pretty happy with the results this time. 

The main issue with my paint setup is my compressor doesn't have enough flow to properly atomise the paint. I've got a Nova 1 HVLP and HY27550 11CFM compressor. On paper it should work, but in reality I only get enough pressure to atomise properly for a couple of passes. So I was compensating by thinning out the paint to around 25% which caused the runs. 

My solution is to run it at full pressure, ensure the compressor tank is full before starting a panel and pausing to let it refill whenever possible. I've dialed back the thinners to 18% and dial the fan in 1 turn. The results are a lot better, there's some texture which I will have to polish out, but I've got zero runs.