Pickup project

[Dan@pickup]

Here is my pickup

Its pretty rotten, someone has previously patched it up but its not great

[Dan@pickup]

So lets get started, front end off for rot inspection, wings will be chucked, have new wings ready to go on after few repairs

Excuse the welding, was blowing holes when I started

Next

Bit tidier

[Dan@pickup]

Mainly just surface rust on n/s/f inner wing so just needed a little rub down, primer and a touch of sealer,

unfortunately the other side was worse, needed a section cutting out and plating, will get pics up soon. Don't get as much time as I would like to spend on this but I will just do a bits when I can.

[Dan@pickup]

Could do with new rear turrets but after searching looks like nobody makes them! If thats the case then I am looking to repair them something like this;

Looks well made!

[rv125]

Congratulations for taking this on and saving another of these excellent pickups. The inner rear wings can be found in eastern Europe. you'll have to work hard to find them. I rebuilt my inner wings a section at a time working on the Weld a lot and grind it back theory making templates and learning the dark art of sheet metal bending in three separate directions they were quite good by the time I finished luckily my neighbours don't mind the sound of the angle grinder. Keep us posted on your progress

[Dan@pickup]

luckily my neighbours don't mind the sound of the angle grinder.

Haha! I emailed a company in latvia today for a price on a new bed section, rear inner and outer wings. No doubt it'll be too expensive! I'm toying with the idea of a sheet metal bender but I'm limited on space. Always wanted a pickup and I'm loving owning one.

[TeflonTom]

Mk3 golf hatchback rear turrets are very similar, go up the scrapyard with a reciprocating saw and chop them off a scrapper.

[Dan@pickup]

Mk3 golf hatchback rear turrets are very similar, go up the scrapyard with a reciprocating saw and chop them off a scrapper.

That's good to know thanks

[goodchoice]

Looking forward to see how you approach those rear turret repairs, watching this closely. Thanks for the pics.

[rv125]

I cannot find the photographs of the rear wheel arches when I repaired them when I do I will post them I wasn't as lucky as you as both front inner wings were in a bad state I used a piece of plywood and a jigsaw to cut the shape I required and bent the metal round it maybe you could do the same it was successful

 

 

 

 

 

 

Edited 3 March, 2015 by rv125

[rv125]

Not wanting to take your thread over but sharing things that work always helps others, the front crossmember was also in a bad way the truck lived on a farm for several years and it had obviously hit a few rocks in the fields over the years this is how I pulled it back into line with my home-made body jig

 

 

 

[Dan@pickup]

I cannot find the photographs of the rear wheel arches when I repaired them when I do I will post them I wasn't as lucky as you as both front inner wings were in a bad state I used a piece of plywood and a jigsaw to cut the shape I required and bent the metal round it maybe you could do the same it was successful

 

spain and truck 005.jpg

 

spain and truck 008.jpg

 

spain and truck 010.jpg

 

059.jpg

Wow, I thought mine was in a bad way, that first inner wing pic brought a tear to my eye! I doth my hat to you sir, some good quality repairs there. I will be checking out your build thread for more ideas.

[TeflonTom]

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mine were pretty bad too. I got some L shaped repair section from the bodyshop next door and chopped out all the rotten stuff.

[Dan@pickup]

^^ Nice repair, is that using 1mm steel? Good to see so many of these being rescued, just a shame skoda didn't slap a bit more primer on them in the first place.

[TeflonTom]

Yes it was 1mm right angle repair section, you can buy it from most panel suppliers, or I guess yoi could make it pretty easily if you have a metal folder, there were none of these captive nuts left that hold the wings on so I had to use self tapping socket head screws.

[Dan@pickup]

Yes it was 1mm right angle repair section, you can buy it from most panel suppliers, or I guess yoi could make it pretty easily if you have a metal folder, there were none of these captive nuts left that hold the wings on so I had to use self tapping socket head screws.

I have just bought a few of those captive nuts from tps as a few of the wing bolts were corroded in them. Also I'm lucky my inner wing square holes are still intact to house them. Part no. for these if anyones interested D0867059, listed as cage nuts on etka

[Titanium_Man]

I love threads like this.

Great work so far. Will be keeping a keen eye on this one.

[TeflonTom]

The other thing worth doing while you havevthe wrlding torch out is to reinforce the front lower crossmember, Its the weakest part of the whole car.

[satchellm]

The front cross members are very weak especially with the use mine gets, I removed it completely and replaced with a piece of galvanised 30x50mm box, ties the front end together lovely especially with the sump guard mounted up I'm sure its made it handle better!

[paul12]

   hi that's how I did my rear turrets    kept it looking as they should 

 

 

http://www.briskoda.net/forums/topic/300522-rear-wheel-shock-mounts-having-fun/

 

 

 

[Dan@pickup]

I love threads like this.

Great work so far. Will be keeping a keen eye on this one.

Thanks, progress will be slow as two young kids and running a business leaves me very little tinkering time!

[Dan@pickup]

The other thing worth doing while you havevthe wrlding torch out is to reinforce the front lower crossmember, Its the weakest part of the whole car.

The front cross members are very weak especially with the use mine gets, I removed it completely and replaced with a piece of galvanised 30x50mm box, ties the front end together lovely especially with the sump guard mounted up I'm sure its made it handle better!

I haven't really looked at/noticed the front cross member yet. The list of repairs grows haha. Added some genuine skoda front shocks to the pile of new parts to be fitted once the de-rusting process is done.

[Dan@pickup]

Managed to get a couple hours on the pickup today, rotten sill:

Rot cut out back to some fresh metal, inner sills look fine although theres a bit of rot behind a previous repair (last pic)

New bit of sheet fab'd and shaped to fit

Bit of primer, Ready for filling and smoothing eventually

thats it for today

[TeflonTom]

Nice job you've done on that. Pushing the weld bead uphill by the looks of it.. odd what you can tell looking at pictures isnt it.

something else I thought of too, make sure you trial fit your new wings before you paint them, pattern part wings for these can vary massively in thier fitment, I had to trim mine to get them to fit around the inner wing spars and had to use a bit of persuasion for them to sit down flush with the door.

[Dan@pickup]

Had another go on the pickup today, first up a diy sheet metal bender was fab'd

N/s/r rot inspection, the arch needs replacing:

The sill has previously been patched:

N/s/r turrett:

Cut back to fresh steel

I didn't get as much time as i would of liked today so never managed to get any welding done. I cut and shaped a replacement turret piece:

I plan to save the top shock bracket if I can, i cut it out and started to de-rust it.

Got the 60mm lowering spring and new front shock on while I have this side up and before i bolt on the new wing. Excuse the state of my garage

That's as far as I got, the mrs dragged me to tesco and then b&q to look at new kitchens!

I also purchased a felicia estate rear wing off of fleabay and will try and fettle that in at some point