16 replies to this topic

[TwoMonths]

Model: Mayfair
Year: 1991
Top engine steady lower bracket is snapped off at the bulkhead - want to weld it back on but worried about proximity to things that might go bang

I'm biting the bullet on my engine steady and accepting it needs a new upper bracket and something done about the lower one. Not actually sure whether to buy a new lower one to weld on or try to patch the old one (£7 for a new one seemed a bit steep - and yes I am that tight).

Really though I would like advice on being safe when doing this (It'd be nice not to kill the car). I've scanned the FAQ but apart from advice about not frying your ECU in a injected model (which mine isn't) I've not seen anything.

Any comments on or close to the topic welcome.

TIA,

/Andrew (and Chippy)

[Guess-Works.com]

Tell you what I did about 10 years ago...

Got a piece of angle iron, cut it to the right shape, and then bolted it to the cross member with a plate on the other side ( behind the pedal box )

Aint shifted since...

[Cooperman]

As it's being welded onto the tranverse box-section, there will be no flamable material behind it. However, remove anything which could burn and cover the hydraulic resevoirs (brake fluid does really burn!). Wash any oily muck off before welding and make sure the ares you are welding are good clean bare metal - you can't weld rust or paint!
Have someone there with a large fire extinguisher as a 'Fire Marshal'. Tinfoil is a good barrier to put around the areas adjacent to where you are welding.
That job is easy if the engine is out, but access an be a bit tricky with engine in-situ.
Good luck with the job.

[MRA]

This sounds like it needs ...... don't weld and drive

use scraps of metal to keep direct metal sparks from areas of danger, keep all the lids on your reservoir, keep a fire extinguisher handy, and keep a friend about who can "spark watch" inside the car as well as outside.

[mk=john]

Model: Mayfair
Year: 1991
Top engine steady lower bracket is snapped off at the bulkhead - want to weld it back on but worried about proximity to things that might go bang

I'm biting the bullet on my engine steady and accepting it needs a new upper bracket and something done about the lower one. Not actually sure whether to buy a new lower one to weld on or try to patch the old one (£7 for a new one seemed a bit steep - and yes I am that tight).

Really though I would like advice on being safe when doing this (It'd be nice not to kill the car). I've scanned the FAQ but apart from advice about not frying your ECU in a injected model (which mine isn't) I've not seen anything.

Any comments on or close to the topic welcome.

TIA,

/Andrew (and Chippy)

Also, you might be better removing the bonnet to get as much access as possible. Things will get pretty tight, and you will need plenty of daylight to see what you are doing properly. With the bonnet removed you can see things much clearer including welding. Never the less, remving the bonnet helps with access anyway.

Edited by mk=john, 20 April 2010 - 08:29 PM.

[bmcecosse]

If doing electric welding - be sure to disconnect the alternator and any radio etc.

[JOC]

A few tips
1) Clean any paint and oil back from around the area.
2) Use an anti spatter spray and cover anything you value as molten balls of steel tend to pit anything in thier path.
3) Have a CO2 fire extinguisher within reach with a 2nd person handy to spot anything that catches fire in car or in engine bay.

Anything I have missed ?
Anything electrical you value should be discounected unless you are 100% certain the ground point for the welding equipment is good.

Edited by JOC, 20 April 2010 - 09:32 PM.

[TwoMonths]

Thankyou! to all everyone that has responded.

• The bonnet removal sounds like a great idea (apparently it's just a few bolts).
• I have an (admittidly old) fire extinguisher and again having someone watching over with that in their hand sounds like a good idea.
• Tin foil - another great idea
• Yes it will be electric (MIG) welding so...
• ...Electrical disconnection - I didn't know about that. I'll look up how to disconnect the alternator. I belive disconnecting the battery would be a good idea too? Umm there's a radio in there (never used it) so I'll disconnect that too. Is there anything else electrical?
• I will be replacing the top bracket at the same time, so should have made a bit more space by taking off brake reservoir and clutch reservoir (and anything else I can find instructions about)
• I think I need to do this inside, but I will try to get as much light to work by as possible

I'm kinda scared, but at the same time itching to have a go - though I'll probably get stuck waaay before the welding and feel like crying. If I get through it and I hope to, it'll have been one hell of a learning experiance.

[sonikk4]

Thankyou! to all everyone that has responded.

• The bonnet removal sounds like a great idea (apparently it's just a few bolts).
• I have an (admittidly old) fire extinguisher and again having someone watching over with that in their hand sounds like a good idea.
• Tin foil - another great idea
• Yes it will be electric (MIG) welding so...
• ...Electrical disconnection - I didn't know about that. I'll look up how to disconnect the alternator. I belive disconnecting the battery would be a good idea too? Umm there's a radio in there (never used it) so I'll disconnect that too. Is there anything else electrical?
• I will be replacing the top bracket at the same time, so should have made a bit more space by taking off brake reservoir and clutch reservoir (and anything else I can find instructions about)
• I think I need to do this inside, but I will try to get as much light to work by as possible

I'm kinda scared, but at the same time itching to have a go - though I'll probably get stuck waaay before the welding and feel like crying. If I get through it and I hope to, it'll have been one hell of a learning experiance.

Don't be scared all of the advice you have been given covers what you need to do, primarily disconnect the alternator and battery. Do make sure all your fuel lines are good and not leaking seeping. Cover the engine with a blanket to prevent sparks covering it but be careful that it to does not burn.

If you can get a proper fire blanket that is used in industrial kitchens even better. Do take the bonnet off it will make your life so much better. Cover the windscreen as well as welding spatter/grinding sparks will damage it.

If you do remove the brake and clutch reservoir thoroughly clean up any brake fluid. it will burn.

Other than that enjoy it might look messy when you weld but practise makes perfect, as long as the weld penetrates you can clean up with a grinder.

[mk=john]

Thankyou! to all everyone that has responded.

• The bonnet removal sounds like a great idea (apparently it's just a few bolts).
• I have an (admittidly old) fire extinguisher and again having someone watching over with that in their hand sounds like a good idea.
• Tin foil - another great idea
• Yes it will be electric (MIG) welding so...
• ...Electrical disconnection - I didn't know about that. I'll look up how to disconnect the alternator. I belive disconnecting the battery would be a good idea too? Umm there's a radio in there (never used it) so I'll disconnect that too. Is there anything else electrical?
• I will be replacing the top bracket at the same time, so should have made a bit more space by taking off brake reservoir and clutch reservoir (and anything else I can find instructions about)
• I think I need to do this inside, but I will try to get as much light to work by as possible

I'm kinda scared, but at the same time itching to have a go - though I'll probably get stuck waaay before the welding and feel like crying. If I get through it and I hope to, it'll have been one hell of a learning experiance.

Hi
Well, a lot of people think MIG welding is a black art. While you can gain advice on here, read books and go on courses, you will find that with practice you can `feel' when a weld is going well. You will develop a sense for just how quickly to move the torch in order to get good penetrating welds, without burning right through. You cant be taught how to develop this `feel', but it will definitely come with practice.

Most people when they start out, don't have a hot enough weld (resulting in a weak weld which does not penetrate, as their first instinct tends to pull away from the weld, rather than committing to it. You should practice, practice and practice more.

[TwoMonths]

Update: Parts ordered from minispares.com

Watch this space

[Bergy]

Thankyou! to all everyone that has responded.

• The bonnet removal sounds like a great idea (apparently it's just a few bolts).
• I have an (admittidly old) fire extinguisher and again having someone watching over with that in their hand sounds like a good idea.
• Tin foil - another great idea
• Yes it will be electric (MIG) welding so...
• ...Electrical disconnection - I didn't know about that. I'll look up how to disconnect the alternator. I belive disconnecting the battery would be a good idea too? Umm there's a radio in there (never used it) so I'll disconnect that too. Is there anything else electrical?
• I will be replacing the top bracket at the same time, so should have made a bit more space by taking off brake reservoir and clutch reservoir (and anything else I can find instructions about)
• I think I need to do this inside, but I will try to get as much light to work by as possible

I'm kinda scared, but at the same time itching to have a go - though I'll probably get stuck waaay before the welding and feel like crying. If I get through it and I hope to, it'll have been one hell of a learning experiance.

Don't be scared all of the advice you have been given covers what you need to do, primarily disconnect the alternator and battery. Do make sure all your fuel lines are good and not leaking seeping. Cover the engine with a blanket to prevent sparks covering it but be careful that it to does not burn.

If you can get a proper fire blanket that is used in industrial kitchens even better. Do take the bonnet off it will make your life so much better. Cover the windscreen as well as welding spatter/grinding sparks will damage it.

If you do remove the brake and clutch reservoir thoroughly clean up any brake fluid. it will burn.

Other than that enjoy it might look messy when you weld but practise makes perfect, as long as the weld penetrates you can clean up with a grinder.

Hi

Can I ask why it's best not to remove the bonnet?

If it's to do with getting everything lined up afterwards, may I ask how best to replace the scuttle and both wings, as I'm presuming the bonnet will have to come off to do these. In which case is there any advice in getting everything lined up and square?

Thanks

[TwoMonths]

Can I ask why it's best not to remove the bonnet?

I don't think anyone has said that?

[sonikk4]

I definetly said take the bonnet off it will make your life so much easier.

[Bergy]

I definetly said take the bonnet off it will make your life so much easier.

Oops yeah apologise folks I mis read it completely. In my defence though I read it at work and I keep the web browser window small

Cheers