48 replies to this topic

[george66]

Well so much for trying to update every week, but, better late than never.

Managed to cut out the rear tunnel that didn't seem worth saving


And fit one from a wrote off MK3, after removing the square end and reshaping to round


Repair piece added in


Cleaned off and etch primed, still needs a bit of shaping, will do that when crossmember gets cut out, pop rivets holding it in place, will be removed when new cross member goes in


Welded in piece of 1x1 box section as a guide for lining up the tunnel, before cutting out the old one.


Seems to fit nicely at the crossmember


And to finish the day off, I made a couple of stiffeners, from some 1.7mm offcuts, for the new boot floor that will be going in



Hopefully it won't be another 4 weeks before I do the next update.

Edited by george66, 17 April 2013 - 03:47 PM.

[Gadgets]

Keep going! every job you do is one less off the tick list!

[george66]

Got a couple of hours in today, cleaned up the remains of the old boot floor and dropped in the new one for a trial fit, it fell into place


Doesn't look too bad from this angle


This one hole doesn't quite line up properly. Have left original brackets on for lining up purposes


Spot on, on this side. Will know for definate when I lift subframe into place


Internal view


Not sure if I'm gonna use it or not, but, I do have a genuine boot floor, never fitted, complete with the fittings, extension and supports (seen at top of 1st picture), but it has been badly distorted through heat, as whoever welded the extension and supports, welded them continuously and along both edges, probably wouldn't have been too bad if it had been allowed to cool down between welds.
I may have a play around over the next couple of days and see how it fits and if it will straighten out.

Edited by george66, 20 April 2013 - 07:53 AM.

[george66]

Bit more done, thought I'd try and repair the rear lower corners, flattened the lip out

 

cut 2 pieces of metal and welded them together

 

Bent a new lip

 

other side and excess weld cleaned off

 

Lined up

 

Tacked in place

 

Welded, ground off, and finished with a 180 DA pad, suppose I should think about getting a 3" mini  sander for doing these jobs, 6" is too big for some places, still got the end to sort out at wheel arch, can do that when I replace the inner arch

 

Also decided  to go with the genuine boot floor that  I already had, here  it is showing it's distortion

Straight edge to show how bad it is

 

How much weld is needed to hold on a support bracket

 

Distorted piece cut off

 

Stiffener brackets zinc primed before welding in new piece

 

New piece is welded in place, just forgot to take a picture, will upload tomorrow if I get chance

[minimikej]

Quality fabrication and finishing, very impressed!

[jagman.2003]

Coming along nicely.

[george66]

Not much done in the last couple of weeks, been helping a friend fit his kitchen, but every little helps

 

Boot floor repair that was done at last post update, need to remove and refit the rose with plug weld in stead of continuous weld

 

Small piece repaired below O/S/R light - before                                                                        After, have done the N/S/R as well

 

 

 

O/S/R boot floor to arch to rear backrest stiffener/strengthener repaired, just need to clean off the surface rust.

 

Also made a start on repairing the lower back rest, have got half of this repair done, just not got anymore pics

 

Rear slam panel is also repaired and welded in place, again forgot the pics.

                                                                         

 

 

 

 

 

 

[george66]

Afternoon again,

it's been a while, so thought I'd better get some more done, not much, but intend for that to change this week, though, knowing my luck sommat will stop me

Managed to get out on Friday and chop off the O/S oversill

 

I then cut out the inner A-post and recycled one that I'd cut from from another shell

 

And today I welded in the A-post and step, and test fitted stiffener (also recycled), will leave grinding down plug welds till tomorrow.

 

Also got my new nuts n bolts delivered a while ago

 

 

[freaker]

u used a part of your new boot floor to repair the old ? 

 

or made a new piece for the old distorted one ?

 

freaker

[george66]

u used a part of your new boot floor to repair the old ? 

 

or made a new piece for the old distorted one ?

 

freaker

Made up a new piece, have still got the other boot panel, it might get sold on if my cousin doesn't need it

[freaker]

if it doen`t get sold i may be up for it :)

 

freaker

[george66]

Bit more done today

Ground down the plug welds on the A-Post.

Cut out O/S floor pan and roughly fitted new one

 

 

Not sure if I should fit the heelboard before the floorpans or not, gonna have a browse of some other threads and see how others have done it

[ToM 2012]

wow! nice work we are pritty much replacing the same panels so i will keep a eye on how you clamp things together and what bits you do in order. thanks tom 

[minimissions]

That is looking like a nice project and nice to see another Hornet being rebuilt :)

[Archived1]

Great work. Decent quality build. well done