2 * 2.1 SD

[Dieselman]

Second coat of paint turned out not too bad. These corner spheres are IFHS spheres, the regulator is a Citroen one, but IFHS coding is easy to understand, so I marked them accordingly. 2* XM30RH, 1* XM50AR

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The fuel tank support straps and rear spheres went back on. The tank straps were a bit challenging as the tank had sagged due to only being bolted at the sides, for several weeks. I had to prop the tank up to be able to install the strap bolts.

I cleaned and greased the end of the suspension cylinder, to ensure the sphere fitted snugly and stop any corrosion. I recently was informed of a Cx rear cylinder suffering sudden and rapid fluid loss due to the end of the cylinder having corroded. Xm rear cylinders are mounted in a more shielded position, but still near the back wheels.

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Followed by the exhaust.

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[Dieselman]

As the rear wheel-arch liners are out I took the opportunity to check for rust. All is generally in good order with a little surface rust at the bottom of the Rh wing/sill section.
After giving this a good wire wheeling it revealed a pin holed area at the bottom of the sill, about 10mm square.

Most of it looks pretty good. I'll weld in a patch to the holed section and seal, prime and paint the rest.

I am particularly interested in the joint between the lower wing and the sill, as that lets water in which causes the lower wing area to rot. The seam sealer has broken down a little, so I will deal with that.

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Some surface rust on the inside of the sill.

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After a good, wire wheeling a pin-holed section appeared, the rest cleaned up.

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[Dieselman]

I cut out and patched in a new piece for metal for the sill trailing edge. I spent quite some time forming the new piece to exactly match the sill curve and creating the return on the trailing edge, then due to having to hold it free hand and working in a very tight spot managed to not fit it perfectly into the sill.
At least it is the underside edge that is not aligned fully.

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It hen decided to have a good look at the seam sealer inside the lower wing area.

A casual look showed this.

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I dug a pick into the seam sealer and found it was cracked and had come loose from the metal, allowing water behind it which had caused mainly surface corrosion, but a cluster of pin-holes in a localised area.
I drilled through the pin-holes with a burr and welded them up, using a copper plate behind to stop the weld. I couldn't hold the copper tight to the steel so have ended up with a bit of a splatter, which due to tight access is very difficult to grind back. I was grinding back and actually cut through the steel again, so had to re-weld.

I cleaned the metal with mild acid and added fresh seam sealer and a thin skim of filler to fill in weld and grinding marks.

I should have done this with the subframe and fuel filler removed, but wasn't aware it needed attention then.

I've added fresh seam sealer which also forms the bonding for the lower wing to sill join.

At least having found and re-instated the failed seam sealer means water won't enter the C pillar to sill joint and corrode the door shut and sill, which causes extensive corrosion and is a very involved repair.

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