Home repair on large crack to body using carbon
Discussion
Not long after I bought my car I was told that the rear end was lop sided, i.e looking at the car from behind, the drivers side sat lower to the ground than the passenger side! So to fix this they un bolted the very rear bolt that holds the chassis to the body and inserted two metal plates directly over the bolt hole to re level the body again. So naturally we investigated further to see for ourselves what was going on down there. It appeared after some time the body wasnt happy and stress fractured right through the panel! Also as you can amagine the rest of the rear end wobbling around. We jacked the car up carefully on this side and undid the bolt and removed these terrible plates. I dremeled out the crack in the shape of a v to get good lamination. See pic
www.fotango.com/p/eba00286996f00000007.jpg
Once all sanded I placed some anti stick plastic paper over the chassis directly under the crack to keep its shape. I then cut several patches of carbon fibre mat and a few patches of fiberglass mat to fit. Once you add the harder to the resin its all go! I put several saturated strips of carbon on first then fibregalss then carbon again. The secret to good laminating is ensure the ratio mix of resin/hardner is bang on and well mixed in before applying and also squeeze out trapped air bubbles as this causes weakness. See pic
www.fotango.com/p/eba00286996f00000002.jpg
Just before the patch is completly hard, use a rough file and take off unwanted large notches. Once complety hard say after a few hours take some finer sand paper and spray paint for the desired finish.
www.fotango.com/p/eba00286996f00000001.jpg
Once all dried we replaced bolt and lowered back to where its meant to sit (directly on the chassis!) We checked tire pressure and did measurements from ground up on each side and its perfect. So am a happy lady
Cut out a few rattles too!!
www.fotango.com/p/eba00286996f00000007.jpg
Once all sanded I placed some anti stick plastic paper over the chassis directly under the crack to keep its shape. I then cut several patches of carbon fibre mat and a few patches of fiberglass mat to fit. Once you add the harder to the resin its all go! I put several saturated strips of carbon on first then fibregalss then carbon again. The secret to good laminating is ensure the ratio mix of resin/hardner is bang on and well mixed in before applying and also squeeze out trapped air bubbles as this causes weakness. See pic
www.fotango.com/p/eba00286996f00000002.jpg
Just before the patch is completly hard, use a rough file and take off unwanted large notches. Once complety hard say after a few hours take some finer sand paper and spray paint for the desired finish.
www.fotango.com/p/eba00286996f00000001.jpg
Once all dried we replaced bolt and lowered back to where its meant to sit (directly on the chassis!) We checked tire pressure and did measurements from ground up on each side and its perfect. So am a happy lady
Cut out a few rattles too!!
Not long after I bought my car I was told that the rear end was lop sided, i.e looking at the car from behind, the drivers side sat lower to the ground than the passenger side! So to fix this they un bolted the very rear bolt that holds the chassis to the body and inserted two metal plates directly over the bolt hole to re level the body again. So naturally we investigated further to see for ourselves what was going on down there. It appeared after some time the body wasnt happy and stress fractured right through the panel! Also as you can amagine the rest of the rear end wobbling around. We jacked the car up carefully on this side and undid the bolt and removed these terrible plates. I dremeled out the crack in the shape of a v to get good lamination. See pic
www.fotango.com/p/eba00286996f00000007.jpg
Once all sanded I placed some anti stick plastic paper over the chassis directly under the crack to keep its shape. I then cut several patches of carbon fibre mat and a few patches of fiberglass mat to fit. Once you add the harder to the resin its all go! I put several saturated strips of carbon on first then fibregalss then carbon again. The secret to good laminating is ensure the ratio mix of resin/hardner is bang on and well mixed in before applying and also squeeze out trapped air bubbles as this causes weakness. See pic
www.fotango.com/p/eba00286996f00000002.jpg
Just before the patch is completly hard, use a rough file and take off unwanted large notches. Once complety hard say after a few hours take some finer sand paper and spray paint for the desired finish.
www.fotango.com/p/eba00286996f00000001.jpg
Once all dried we replaced bolt and lowered back to where its meant to sit (directly on the chassis!) We checked tire pressure and did measurements from ground up on each side and its perfect. So am a happy lady
Cut out a few rattles too!!
Kylie,
Sounds as if you did a first rate repair. One question though, Esprits are known to experience significant 'spring sagging'. This usually occurs on the driver's side as this is the side that usually bears the most weight.
Are you sure that you didn't merely correct this saggging by adding height to the body? Have you measured the height of the chassis on both sides? Measured the height of each rear quarter panel? Measured the length of each rear spring under the normal weight of the car alone? If these are equal, then you have identified and corrected a different deficiency, if not, you may have to replace your rear springs to get the chassis right...Jim '85TE
Many thanks, will remeasure everything you suggested. The crack had to be repaired regardless and should have never been lifted off the chassis in the first place. Going back outside now with the tape measure 
Someone previously had tried to compensate for spring sagging and had packed the body up causing the crack it is now back down level you misunderstood what I wrote
>> Edited by Kylie on Friday 10th January 10:53
Someone previously had tried to compensate for spring sagging and had packed the body up causing the crack it is now back down level you misunderstood what I wrote
>> Edited by Kylie on Friday 10th January 10:53
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