1498 replies to this topic

[Carlos W]

You've made a fantastic job of splitting it into usable panels mate!

 

I'm really impressed! I hope my grinder is holding out

[Ben_O]

Cheers!

 

I would hesitate to do it again but it is nice to use reclaimed panels and they have come off nicely with no distortion. Just gotta decide whether or not to use one of the quarters as it needs a fair amount of work and i don't really want joins in the panels, even if they will be hidden inside behind trim.

 

Just the rear bins, inner sill stiffeners, waist rails and seat brace to go and then i'm done.

 

Ben

[JonnyAlpha]

With alot of patience quniton1275!

 

Started out with the rough distributer casting which is pictured above. I clamped it down to my bench to stop it moving and then used a flat file to remove the casting marks that run the length of the casting on each side.

Next i used a piece of 80grit sandpaper on a rubber block to take out all of the scratches and the rough texture but tried to avoid too much working where the engraved lettering and numbers are as i wanted to retain them. Once it was uniform all of the way round and free of as many marks as i wanted, i went over it with a piece of 240 wet and dry on a block but used it dry to take down the 80 scratches.

Next i went over the whole thing again with 400 grit wet and dry, again using it dry on a rubber block until the 240 scratches were gone and then finished it off with one of those foam abrasive sanding sponges for decorating. It was 800 grit and i found it very good on the cylindrical casting as it is flexible.

 

Once it was sanded back fine you get the appearance almost like brushed aluminum but to get the shine, i just stood it up on the bench clamping it upright with a large g clamp to the bench and then spread some Farecla G3 cutting compound on the housing and then slipped a piece of cloth over it and then holding both ends of the cloth, pulled it back and forth with quite high pressure moving round the circumference of the housing until you get a desired shine.

The polishing method i used is very hard to explain but hopefully you get it!.

 

Once i was happy, i used a finer compound. I could have gone ALOT further and had it looking like chrome but it's not the look i want and i don't have the patience to polish it that much by hand.

Looking back at it now, i'm not 100% happy with it and it will probably get re-done. Infact the more i look at it the more i pick holes. It could be alot better.

 

The carb was a similar affair  but for the main body of the carb i used a plastic bristled wheel in a drill to clean the muck off and brighten the ally up but be careful as the plastic brush in the drill can easily smudge the cast alloy and it looks terrible.

Got the dash pot, i used the same method as the distributer and for the float chamber was a combination of the foam abrasive sponges and the plastic brush.

 

Note though that i didn't actually polish anything on the carb apart from the dash pot.

 

Thanks for looking and if i can help explain anything better, please ask.

 

Ben 

Was going to ask exactly the same question as Quniton1275, a lot of hard work and elbow grease but worth it in the end.

I was looking for a tip on cleaning ally back along and came up with Toothpaste, something like Colgate Whitening is best, I Googled 'Aluminium Cleaning' and got a mirriad of results, some better than others and some detrimental so watch out.

 

Keep up the good work 

[JonnyAlpha]

Bit more done

 

 

Getting closer now and the pile of panels is growing.

 

Ben-O

 

Good work resurrecting those panels, its like watching re-incarnation of a Mini, better than being crushed for scrap!!!

I have a little experience of separating panels and I know how difficult it is not to damage anything while you are doing it, lots of careful drilling with a Spot Weld Drill,

How many Drill Bits have you gone through???

 

I just got a Drill Sharpening Guide from Axminster Tools for Fathers Day, only thing is no one bought me a Bench Grinder DOH!!! 

[Ben_O]

 

Bit more done

 

 

Getting closer now and the pile of panels is growing.

 

Ben-O

 

Good work resurrecting those panels, its like watching re-incarnation of a Mini, better than being crushed for scrap!!!

I have a little experience of separating panels and I know how difficult it is not to damage anything while you are doing it, lots of careful drilling with a Spot Weld Drill,

How many Drill Bits have you gone through???

 

I just got a Drill Sharpening Guide from Axminster Tools for Fathers Day, only thing is no one bought me a Bench Grinder DOH!!! 

 

Hi mate.

 

cheers for the compliment. 

 

It is taking much longer than i thought it would but it is really tricky to get right. I haven't been completely successful as some of the seams in places are torn a bit but i'm not worried. By the time i cut out and replace the thin pitted areas of seam and weld up the drill holes and grind back it will be as good as a new panel.

I will also be paint stripping them and closely examining for any traces of rust.

 

As for spot weld drills, i just used a few old ones that i have had for years and use often. They are very expensive ones and have been sharpened several times. It pay to get the good ones if you will be using them alot. Cobalt tipped wurth drills are good.

 

To be honest though, i haven't used a spot weld drill for much of it as the wheel arch seams and vertical rear seams have elongated spot welds which don't drill with a standard spot weld drill. So i used a 6mm drill bit to drill both skins on most of the seams and just work slowly drilling 3 welds, splitting those 3 welds and then the next 3 and so on.

 

For the wheel arch seam, i decided that i didn't want to save the wheel arch tubs as they are quite badly rotten so i just turned the shell upside down  cleaned the underseal back from the underside of the arch seam and then used a thin cutting disc in the grinder to cut a slot all the way along the seam and the depth of the arch skin. then just split it. 

 

Ben

[Ben_O]

So i have now finished salvaging what i can from the half-shell and am satisfied with what i have got.

 

In the end, i got the rear seat brace, one rear bin, parcel shelf, rear panel, both quarter panels, both waist rails, both b posts and the roof as well as some odd brackets and bits.

 

I couldn't fit the remains in my car so i put it out the front with the bins for now and a man knocked the door this morning with a transit tipper and asked me if he could take it. Result!

 

so all that remains now is to cut the roof in half this afternoon so i can get it in the car and then the fun begins with repairing the panels. Not much really, just need to weld up the drill holes where i drilled the spot welds and a few small repairs and they will be as good as new after a through strip and etch prime.

 

I will try and get some photos up this afternoon too.

 

Ciao

[Ben_O]

Pictures!

 

 

Overall very pleased. Really picked it dry!

 

All that was left was the rotten boot, floor, rear half of the main floor, one of the rear bins and both arch tubs which has now gone.

 

Ben

[Carlos W]

Good effort mate

[Ben_O]

Good effort mate

cheers mate. you still popping round?

[Carlos W]

Good effort mate

cheers mate. you still popping round?

Yeah, won't be long

[Ben_O]

got time for a coffee?

[Carlos W]

got time for a coffee?

Always

[Palmer02]

Excellent work, can't wait to get started now

[Ben_O]

Excellent work, can't wait to get started now

cheers!

 

Can't wait to get on with mine! been away too long...

[Covert]

Awesome work as usual ben, keep up the good work!