fixing the 2nd insignia 2.0t 4x4

evocarlos

Stupid Bollocks
Staff
#1
after picking up an accident damage 2011 insignia 4x4 1 of 10 now 1 of 8 i decided to fix it up and use is as daily car
here are lots and lots of pic from the last couple of months

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it came on the back of a truck with to my only surprise a gen3 block the LDK engine
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lots of little bits to fix
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holes and scratches on most panels
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had to cut the tyre off the wheel to drive it off the truck
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it was pretty beat up
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lower wishbone bent
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main cooling rad poped
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10ton jack kit pushing it straght
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getting close
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very close to the original position
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long way to go
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plenty to do on the inside to
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a very good friend of mine called me to say he was breaking an insignia so i rushed up there to scavenge some parts
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took the trusty plasma cutter and bought the front corner home
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at least if i needed any metal parts i have all the bits to replace the damaged parts
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bumper headlight and a long list of parts in stock and ready to be fitted
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diesel a/c pump to replace the one i used for the astra
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crash bar and the extensions
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inner tie rod was bent so that got replaced
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as the car was ex police i took to decommission it as a police car and removed all the extra wiring
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getting there
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replaced the broken headlamp plug
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even more wires
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took the seat and carpet out then wet vacced them
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chop chop more wires coming out
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replacement door on
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a complete car again on the outside
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stud welder to try and fix the sil
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close but no cigar
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5 control units hidden in a bracket behind the dash
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i guess that all of it
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engine bay cleaning
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that will do me
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more carpet cleaning
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found enough change in the car to buy a new front number plate
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back seats were a mess
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up front looking better
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back seats now clean
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took the blue light out the head light then sealed it up
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serviced the haldex clutch
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normal dirt in the case
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didn't have time to wait for a new filter from europe so cleaned it out
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had enough oil left over from doing the other diff
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new cabin filter and aircon bomb to freshen the inside up
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also got the dvd800 head unit the car never came with a radio just got to get this one decoded and recoded to this car
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nearly time for mot
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it passed the mot and then got a replacement bonnet
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even got a different bumper without the anpr holes in
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front pads were past there sell by date so stripped the twin pot TRW calipers and cleaned them up
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disc hub and edge painted to give it the fresh look 337mm discs :)
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genuine TRW pads altho not the TX range
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sliders were bit dry
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i do like a clean set of brakes :)
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drivers side looks like it had a sticky pad
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before
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after
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after after
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now on to the body work the police aerial had to go but put a blank in a welded it in place
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what hole lol
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quite a few dents in this side
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trying to keep the body line
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other side was even worse
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guide coat to find the dips and bumps
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like that
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nearly done
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rear bumper had a nasty score mark
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plastic filler
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prepping for paint
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colour going on then top coat
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nice!
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at 1st i thought the back end was bent turns out i had not fitted the bumper in the slot right DOH!
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moving onto the rear quater
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thats made that bit look great
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pretty close match to the original paint
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and at least its shiny
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now to fix the dented sil got a whole sil as a replacement
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rear door off for better access
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chop chop
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the door jam was bent in a little some angle iron show the extent of the damage
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not any more
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repair patch cut from the replacment sil
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made sure it all lined up
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inside was cleaned and painted with cold galvanizing paint
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factory stone guard removed
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test fit
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tacked in place
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fully stitched in the weld sits under the rubber door seal
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under side welded the same
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upol #10 stone guard applied to match the factory stuff
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cant wait to get this full side painted
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more soon :)
 

evocarlos

Stupid Bollocks
Staff
#2
had a run down to portsmouth to fix a z22se in distress
loaded up the huge boot let some air out the tyres
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after a good run down even with the boot full it managed 36mpg the same day i drove over to perranporth but got excited and hit the sport button the mpg soon dropped down to 30 but was worth it :)
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now im back its time to do more of the body work
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dinks in the door done
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reshaped the arch also had a bit of filler that didnt go off so dug it out
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drivers side dings
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passenger side almost ready for paint
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dings on the door look to have gone to
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evocarlos

Stupid Bollocks
Staff
#5
looking good, I like the new wheels :D
had to borrow them from the other one there worth more than what i paid for this one lol
Just needs some leather seats or some nice Recaros :love:
i had looked at a set of vxr recaros but there horrid looking and almost 1k to buy the seats that are in are great did 9 hours behind the wheel last friday and never felt fatigued at anypoint.
need to fix the dash loom and get the dvd800 recoded can't seem to connect to the head unit thru the obd port
 

evocarlos

Stupid Bollocks
Staff
#6
the black bonnet is now the right colour inside and out :)
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did a layer of primer
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guide coat then flatted it back
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paint went on a little dry and thing my gun was dirty got a few stripes
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out the gun finish was good on the laquer
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car has faded over the years soon be one colour once i get the sides sprayed :)
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evocarlos

Stupid Bollocks
Staff
#7
bumper and mirror covers time for paint

stripped the bumper to the bare shell then washed it clean
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loads of bit to come off
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quite a few nasty marks to fix
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bumper filler and high build primer
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same for the mirror covers
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base coat on
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laquer
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grills reinstalled in the bumper
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wings are now off ready for prepping and painting today :)
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evocarlos

Stupid Bollocks
Staff
#8
drivers wing had some damage the hammer and dolly got most of it out
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prepped all the panels with 180 grit on a 70mm da
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high build primer and guide coat
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glad to have kept the shape of the drivers wing
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after wet sanding
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base coat and lacquer going on
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again the out the gun finish is great
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after a few hours when they were dry the got refitted to the car
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took ages to get the gaps right
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im not unhappy about how the wing came out considering the damage
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recap before and after :)
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#10
Its been a while since ive posted on here but ive been reading loads. Ill tell you what Carl you have done an amazing job on this (and the others you have done). Is the astra on the back burner now?
When can i book you in to spray the zaffy lol
 

evocarlos

Stupid Bollocks
Staff
#11
That's some good work there Carl. Are you painting all the panels outside?
thanks :) yes with every panel marked in some way all the out side will be painted it will also make the car one shade the new paint is slightly darker

Its been a while since ive posted on here but ive been reading loads. Ill tell you what Carl you have done an amazing job on this (and the others you have done). Is the astra on the back burner now?
When can i book you in to spray the zaffy lol
thanks ive had fun working on it :) the astra is at the run-in stage its all back on the road now just need to get some miles on the engine then finish the mapping part
not sure i want to start doing spray jobs lol
 
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