I've always wanted a 309 estate and first thought about how to make one about 15 years ago (when I was 12!). Here's a few pics of the build which I started in October 2017. Still need to finish the headlining and trim, but all the electrics work (wiper, hi-level brake light, washer, heated screen, keyless entry).
It's my first go at any sort of bodywork/coachbuilding/spray painting/steel rolling. I used non-isocyanate 2k paint to start with but it never cured even when baked. So I got a refund and went with proper 2k and built my own air fed setup using a blower motor and a drainpipe!
It's been my daily drive for about 3 years, doing about 20k miles a year, and it will continue to be a workhorse, even more so now!
Donor car bought for £80 (happens to be LHD):
Early brainstorming
Started cutting the tailgate to give more boot space
Welded the new piece on, keeping the heat distortion to a minimum
Box section and angle stiffeners
Plug welded the roof skin on
Added window frames and rain gutter. I had to make all this myself. Folded the gutter on my press brake to match the original profile
I rolled these pieces on my English wheel to get the variable curvature profile, and to get the step in the roof to continue onto the rear section
First trial fit on the actual 309. The donor car was quite badly dented and the Phase 1 tailgate attaches differently so I thought best to check before I went any further!
A thin skim of filler and a lot of sanding, followed by etch primer
More sanding and 2k high build primer going on
Did the bonnet at the same time
It's my first go at any sort of bodywork/coachbuilding/spray painting/steel rolling. I used non-isocyanate 2k paint to start with but it never cured even when baked. So I got a refund and went with proper 2k and built my own air fed setup using a blower motor and a drainpipe!
It's been my daily drive for about 3 years, doing about 20k miles a year, and it will continue to be a workhorse, even more so now!
Donor car bought for £80 (happens to be LHD):
Early brainstorming
Started cutting the tailgate to give more boot space
Welded the new piece on, keeping the heat distortion to a minimum
Box section and angle stiffeners
Plug welded the roof skin on
Added window frames and rain gutter. I had to make all this myself. Folded the gutter on my press brake to match the original profile
I rolled these pieces on my English wheel to get the variable curvature profile, and to get the step in the roof to continue onto the rear section
First trial fit on the actual 309. The donor car was quite badly dented and the Phase 1 tailgate attaches differently so I thought best to check before I went any further!
A thin skim of filler and a lot of sanding, followed by etch primer
More sanding and 2k high build primer going on
Did the bonnet at the same time
