1146 replies to this topic

[sonikk4]

Don't panic over it Hugh but it is well worth checking. It did not take long with a grinder to sort it out.

[myredmini]

Ok Hugh, if you want it just let me know its only sat in the garage..

[Carlos W]

You're progress is so quick mate! I'm definitely going to get down to the garage tomorrow and drill out the spot welds at the front of the passenger floor pan! Every time I look at this thread it gives me inspiration!

[grahama]

The grinder, a mini restorer's best friend !!! If it doesn't fit then just do it again, looking great to me though !!

Graham

[iDemonix]

Only just seen this project and read all the way through, I'll be checking back constantly now!

I'm yet to own a mini, hoping to pick one up the end of this summer or after Uni in a year, I'd love a project but I'm terrified of welding and grinding having never done it, after reading through this thread I'm starting to think that everything can be picked up with enough time.

You're doing an ace job, it's amazing how far you've come in such a short time, definitely keep going and take as many pictures as you can!

[hughJ]

Well, I haven't updated for a while - I had nothing to update. How right these wise people Graham and Neil were. The windscreen did not fit!!! What an absolute downer. So I gave up for a while - a man of weak character.

Thanks Carlos and iDemonix for the kind words - maybe too hasty! The welding is terrifying and I don't know enough. But if you don't try you don't learn and you do learn by your mistakes. Well I hope I do.

I eventually got the grinder out and persuaded the windscreen to fit. I'm not happy with it but time will allow the memory of how bad it is to fade.



And with the bonnet - there is a slight unevenness, hence my son's scooter battery keeping one side down



All I have done since then is fit the under-scuttle closing panels





If I can offer any advice to anyone fitting the windscreen surround panel -

1. If it doesn't fit to the old aperture - force the old metal out to join with the new - not force the new to the old.
2. Plug weld along the underside of the top where it meets the roof, even though upside down welding is difficult.
3. Don't remove the stiffener in the middle of the aperture till it is all welded in - it keeps the distance apart constant.

4. Maybe - don't do it at all - avoid the stress - it's an expensive panel!!

Well I have some new panels arriving - front floors and sills. I do have wings, front panel and Apex panels up in the attic but am going to do them after the underside is repaired, the subframes tidied and back on its wheels.

Not grinding along

Hugh

[grahama]

Hi Hugh,

Oh to be a wise person, and still a novice at this myself !!

sorry it was a trial to get it to fit but fit it did in the end and that is the importnt bit, looks good from here too !! I too find the welding scary, I haven't tried my OS door yet as no hinges so don't know if my welding is ok yet, very scary till I can test, so I know exactly how you feel !!

Nice job on the scuttle closing plates, a job I have comming up. Did you weld to the outer side of the scuttle, plugs look ace but can't see anything else ??

Graham

ps, home made or pattern closers??

pps Give the bonnet a twist, usually sorts out the ill fitting if only the bonnet kinked, worked for me !!

Edited by grahama, 29 March 2011 - 09:29 PM.

[hughJ]

Hi Graham - thanks for the comment. My closing plates were from M-Machine. They are a super company. There are the plug welds you see and there are three plug welds done from the top on the front seam. At the side there is very little overlap so I will just fill with sealant. I have seen elsewhere the closing panels glued on or held on with seam sealer, but I would rather a few welds holding them.

Kind wishes - Hugh

[iDemonix]

Any updates on this project?

[sonikk4]

Hugh don't get down mate believe it happens to all of us on more than one occasion. Just take a deep breath count to 10 think about what happened then sort it out.

Its looking really good and before you know it it will be time for paint which will be the next hurdle.

[WoodlandsMini]

Keep up the good work, goes to prove these things are a learning curve... I learnt from my mistakes along the route

Always love it when I get an email saying this is updated.

Thanks

Matt

[hughJ]

I have been very lazy and a bit disheartened. But after a nice holiday in Reeth its time to try a bit more. (What a smashing area the Dales is. Its far less spoiled than up here in the Highlands. We have pylons, industrial estates and my huge hate, windmills. )

A big thanks for the surprise comments when I opened my topic to update. I thought it would be well forgotten. Thanks Matt, Neil and iDemonix.

I decided to replace part of the driver's side floor.





To fit this



So I cut out a big hole



And did a grotty little repair - need to get the welding going again!!



And trial fitted the cut panel. It is not a great fit but will use Neil's recommended tool - a hammer.



This takes five seconds to explain but it is five hours work.

Well at least I'm moving again. Should get it welded in tomorrow. I can't face going back out to the garage tonight!

Grinding on again

Hugh

Edited by hughJ, 19 April 2011 - 05:55 PM.

[tino]

Looks good, I'm trying to get up the enthusiasm to work on my mini, which like yours has sat in storage for a reasonable amount of time.

Seeing what someone else new to welding does and how they are improving with practice is a giving me the belief that I can do it to ( Not meant in an insincere or condescending manor )

Keep at it and you will get there!

Edited by tino, 19 April 2011 - 06:18 PM.

[sonikk4]

Hugh a few tips with the floor panel.

Tack it all round not too close but enough to support it fully. Those flutes not lining up is best to attack it this way. Tack at the top of the U shape and the bottom of the U shape on one side only, then a tack in the middle. Once that's done then attack the other side of the U with a hammer and block to get it to sit right. Do this on all of them.

I would recommend not seam welding as you will blow through as you appear to be butt welding so pulse weld in 1" sections but miss an 1" weld an 1" etc to minimize distortion. It does take a while but worth it. If you are worried about strength then pulse weld on the underside as well.

[grahama]

Hi Hugh,

Nice work as usual, the advice on the flutes is good as normal from Neil, glad mine are ok !!! I always use pulse welding as it's all I can do . I tried seam welding but with such a simple and cheap welder, Clarke pro 90 fleabay purchase, I found I ws blowing through all the time.

I agree it does take more time but I'm not in a rush as Matt hasn't started to drive yet !! Also I pulse seam all those sort of panels both sides as they are around the driver, my lad in my case, and want it as strong as possible. This also allows a little grinding down too as weld is on both sides.

Just how I do it, but keep at it.

Graham