Club 80-90 Forums

Just got a replacement arch to try and slow the rot most of it being around the filler cap, the rest of the arch is pretty sound, is there any way I could just cut out part of the replacement arch and somehow weld it in?

Sorry file is too big to post the photos, I will work on that.

You will have to take fuel tank out if there is going to be sparks !

Check your seatbelt mount while your looking. If you swap the whole panel its nearly all spot welds so easier to do a neat job. Be prepared for B pillar repairs.
Having said all that I'm still loathed to cut out good original metal.
You'll only realy know when you get the filler pipe and expansion tank off and have a good poke around. The original rubbery underbody protection can hide a lot of nasties!

I cut out the bad bit on mine and cut the arch to fit rather than cut out all the good metal . As for the tank filler tube I stuffed damp rags down the tube then a couple of plastic bags over the end with another wet rag over that you could also put cardboard over that for extra protection . It worked for me I had the wing ,the seatbelt anchor plus a wee bit more ,also foot well and floor and I am still here

Having successfully destroyed a classic 1600e Cortina car, garage and neighbours fence after doing some welding some 30 years ago (and I only survived, according to the fire brigade, because the tank was full, flame couldn't enter the tank to then explode) I still maintain it just isn't worth the risk, but it's your call...

As for the wheel arch, every arch I've done has had unseen rust living underneath the factory sealant so in my opinion, it's a waste off time to not replace the lot and be done with it. Don't be surprised to find more fun on the B post when you cut the arch off...

It is a diesel so no as bad.