I finished the body repairs on my Hyundai Pony pickup...
...primer...
...here the primer is sanded smooth and everything masked up again for painting...
...final paint...
I also repainted the hinges and supports for the tailgate...
Before putting everything back together I rust prrofed inside the body with some cavity wax...
Here's the inside of the tailgate coated in protective wax. These Hyundai Ponys rust easily so it's best to do this...
Here it is with all the parts re-fitted...
Next I have to refit the rear springs and shock absorbers. I removed them to give better access for welding the chassis. I'm glad I did as I found that the rubber bushes were all worn out!
The tailgate on my Hyundai Pony had some bad dents, especially at the top above the handle, and a little rust along the bottom. The picture on the left below shows how it looked when I got the truck. On the right is how it looked after I stripped away the paint and straightened out most of the bad dent at the top. You can see only a little rust along the bottom...
The rust didn't look too bad but after cutting away the outer layer you can see how bad it really was...
After grinding away as much rust as I could, I used some rust remover to dissolve the remaining rust. This kind of product usually contains Phosphoric acid. .It takes a few hours for this stuff to work but here you can see it has dissolved pretty much all the rust...
I painted the inside area with some zinc paint then made a section to repair the bottom edge and welded it in. I forgot to take some pictures here as I was doing it but here you can see the new piece welded in...
On the inside edge, the lip of the repair wass folded over and hammered flat and then welded in the corners...
Next, I had to finish removing all of the dents and use some filler to make the panel straight again...
Then some primer. I used some grey 2k primer made by U-pol....
...and finally some paint. This is 2k paint in the original colour called "Jamaican Blue"...
Yesterday, I went to collect a great set of wheel which I won on eBay.
They are 7x13 Libre replica wheels. American Racing Equipment (A.R.E.) used to make Libre wheels like the ones fitted to the B.R.E. Datsun 510 race car, but these are definitely not made by A.R.E... I don't know the manufacturer as they have no markings on the rear other than the size.
The wheels I bought used to be fitted to a Jomo single seater racing car, which was based on the Brabham BT15/18. They have 4x108 PCD...
The tyres are Dunlop racing tyres so I will need to change those as they are a little bit too wide for my Hyundai Pony pickup. They fit the Pony well and look pretty good....
I need to repaint the centre part of the wheel, polish the rim and try to find some wheel nuts to fit them with. They use a sleeve type wheel nut but I don't think they will be hard to find.
The rust on the right rear chassis on my Hyundai Pony pickup was as bad as on the left so the repair was similar. The only difference was that I had to cut away part of the inner wheel housing to get access to the front end of the chassis rail. I cut it carefully with a saw and welded the section back in afterwards. Here, most of the rust has been cut out and repaired and a coat of zinc paint has been applied...
Finished repair...
There was another area of rust further towards the rear of the chassis rail. Here the outer layer has been cut away and the surface rust treated with 'Kurust'...
Finished repair...
Also, there was some rust in the seam where the rear valance is spot welded to the lower edge of the rear quarter panel. I cut away a part of the valance, and cut out the bit of rust...
.... then welded a small section of metal in and finally welded back the piece of the valance I cut out...
Before I did these repairs,to the chassis, I repaired a lot of rust around the rear wheel arches and sills on both sides. I will upload some pictures of those repairs to the gallery for my Hyundai Pony.
Now, I have to prepare the rear half of the truck for painting!
My Hyundai Pony pickup had some rust in the chassis rails at the rear. It doesn't look too bad in the pictures but it was worse than it looked. Here you can see the left chassis rail...
...and here it the right side with the same kind of rust. The chassis rails are two layers or metal and the rust has started between the layers...
Here is the right chassis rail looking from underneath...
Here is the left chassis rail after I tapped it with a hammer. Holes!
Here's how I repaired the left chassis rail. The outer layer of metal was cut away.In the picture below, I had already repaired a little of the chassis rail underneath...
Here the rust in the inner layer was cut out and all the rust removed...
...and here, new metal welded in...
Then the weld was ground smooth and some zinc paint applied before the outer layer replaced and all the welds ground smooth...
