1146 replies to this topic

[racingenglishcars]

That bonnet repair on Project Erm sounds like the winner here. I am glad I came across this because it's exactly the technique I need for a door fit I need to do right now on my Frogeye.

I'm sure you will pull it off without a hitch. Your welding is really quite good now.

[myredmini]

Looking fantastic Hugh, keep up the hard work

[deebo]

looking great hugh. are you gonna cut the bonnet and extend it in the middle or have i got the wrong idea? lol

dom

[sonikk4]

looking great hugh. are you gonna cut the bonnet and extend it in the middle or have i got the wrong idea? lol

dom

If he is going to follow the technique i used on Project Erm then you slice each side of the bonnet and add a thin strip of steel. Try to add it to the middle would be a real pain plus with the ridge in the middle would compound matters even more.

[hughJ]

Neil so value your comment - you were one of my original helpers and inspirers! Thanks minimuk, racingenglishcars, Dan, and deebo. I'm doing it exactly like Neil extending both sides. Well not exactly like Neil his is an exceptionally tidy job. You will see.

So tackled the right side - slit up the side of the bonnet and cut this wee bit



Tacked and checked gap



And welded - took quite a while





And ground back



But here we go - hate grinding, always go too far

Some holes to fill - another day!



The gap is better. A bit of filler and it will not be too revolting.

Moving along

Hugh

[grahama]

Nice one Hugh, a trickt slither of steel to weld in for sure. Have you just extended the bonner out, (wider), or is there a 'down' bit under the new bit too meeting the inner wing ??

Coming along nicely though !

Graham

[hughJ]

Hi Graham - I've just extended it out. Dear knows what problems I'd cause if I extended it down!

I've done the right side of the bonnet last night and tonight - just the same as the other side. It needed a slightly wider and longer filler piece. Here the edge of the bonnet has been cut and the filler piece.











I hate grinding back my welds. I'm going to have to redo bits like I did on the other side. I wish I was like Scott or minimuk - they seem to use weld like filler and get it to grind back to like it was all the original metal. I can't. But my old friend Isopon will help me out.

I have to deal with the rear of the bonnet - I've just left the strip sticking back at present. Will this welding ever end? I thought I was just about there. I have enjoyed doing these long welds though.

Welding along

Hugh

[Brams96]

Hugh, are you using a grinding disc or flap disc to dress the welds back? An 80 or 100 grit flap disc would be better & sodter on the metal.

[minifcd]

Looks like that will do the job Hugh. Even I need to use filler some times mate.

[minimuk]

Hugh,
Same here, like Scott filler is needed one way or another sometimes, and the more practise you have the better you get at it.

not bad your extensions, I would have taken the bonnet off after 5 or 6 tacks to have those strips in position, then I would welded it from under the bonnet(engine side), then turned it over and would give the cut opening a very thin straight weld 1" and 1" space and so on, from one end to the other, then go back to beginning and weld in between those first welds, only after that I would use a 80 grit flap disk to start sanding those welds back, on both sides of bonnet and use a fleece disk to sand it smooth with a light pressure(Cheers Danny),...and little pits left after that tack those and sand back again.

this area you are doing is not easy to work on so your resuld is not bad at all. what is your welder setting, it looks like the wire speed might be a little to fast, or is it good for you?

Edited by minimuk, 23 March 2012 - 10:34 PM.

[BusheyTrader]

I thought having to cut my flitch repair panel into 3 separate pieces, reprofile them and then weld them back together to make it fit was innovative..................... This takes it to another level

I'd be apprehensive slitting and welding a strip an outer panel in case I distorted it with too much heat. Hopefully I'll get round to the front on mine one day to find out.

Looking good.

Adam

[grahama]

Nice one High,

Worth all the agri now, soon be in paint. Your bonnet may well need a skim of filler, but wait till u see the scruffy repair I did today, I may need a bucket full. Looks like you are finding your feet nicely with the intricate welding, where as I am only finding myself going backwards in finesse !!

Keep it up

Graham

[clovus]

Wow, what a fantastic journey you have taken Hugh!

I ve just read the whole thread. Simply enthralling reading, from being worried about taking the grinder to the mini, learning to weld and then fabricating parts and problem solving. You keep saying it is only for MOT, buy it all looks really good so far and at a very high standard. You must be proud when you have a look at what you have done.

Thanks for documenting everything so thoroughly I have found it inspirational reading.

Cheers!!

[sonikk4]

Hugh the bonnet looks fine. We all suffer from the odd issue with pits in the weld or grinding back too far. You can always add more metal so no worries and also a skim of filler will help cover small sins.

[racingenglishcars]

Looks quite nice. I can't quite see if the gap is even all the way. If it isn't I'm sure you know that a slight manipulation with a body hammer can straighten a small gap problem. Almost paint time :)