3 votes
Mill Road Garage
Posted 06 February 2015 - 07:52 PM
great!
Thanks Jay.
It was just really tricky to see how it would have been fitted at the back because both sides are so badly corroded. There is no way to determine what is boot floor and what is valance close outs as it's just one flaky mess.
Once i get the position of the arch tub set, then i will cut half of the boot floor out in one go just to get rid of it.
Mill Road Garage
Posted 07 February 2015 - 05:23 PM
Been at it again today.
I want to get the shell ready to accept the arch tub so i can get it in ready for the fitting of the heelboard etc.
First of all i set about cutting out the right hand rear seat belt anchorage as it is a bit tired and there is rust beneath it. The mount itself is spot welded to the bulkhead and then there are a few random tack welds and a couple of inch long seam welds holding it to the bulkhead and boot floor.
So i chopped it off ready for the clean up.
Then i gave the whole area a through clean up to see what needed repairing etc
The flange of the rear bulkhead where it spot welds to the arch tub was a bit thin in places and there was some tears/cuts from where i had removed the seat belt anchorage. so i decided that i would make up a new piece to stitch in.
As you can see in this next photo, there is a lovely tear where a seam weld was holding the anchorage to the bulkhead and it was to thin on the edges to weld it up.
I'm quite happy with the fit of the arch tub, it fit's nice and close to all of the places it needs to weld to.
Another close up of that tear and cut
So i made up a cardboard template to follow the existing shape and tried it in for fit.
Then transferred it onto steel
Cut it out and cleaned it back to bare metal
And then using 2 pairs of pliers, i put the fold into it and then finished it off with a hammer and dolly to get this
So then i drew a guide line on the old one so it could be cut out to allow the new one in
And then put some masking tape on the arch tub and re-fitted it so i could draw an outline of the old flange onto it as a guide for fitting the new one
Then i carefully cut it out with a 1mm disc leaving my guide line to work against.
I don't seem to have taken any pics of the next stage but here it is partially welded in and cleaned up
And from the back
I had to stop, because this happened
the next update will have to be after i have got some more wire. Hopefully by then, i will have the other panels too.
Cheers for looking
Ben
Edited by Ben_O, 07 February 2015 - 05:26 PM.
Speeding Along Now
Mill Road Garage
Posted 09 February 2015 - 07:40 AM
If you were near by, i would have a deal with you but i can get a 5kg reel for £13 so it's the postage on yours that kills it for me.
Besides, i use 0.8 anyhoo
Cheers for the offer though!
Ben
Mill Road Garage
Posted 13 February 2015 - 10:03 AM
New wire turned up so i will hopefully have an update later.
Plan is to get the rear bulkhead repair finished, get the arch tub welded in, replace the waist rail and then cut the quarter panel off.
Ben
Mill Road Garage
Posted 13 February 2015 - 06:21 PM
Well it all went to pot today. Probably because its Friday the 13th 
Anyway. I had grand plans to spend this afternoon finishing up the rear bulkhead repairs, getting the arch tub fitted followed by replacing the waist rail and lopping the q panel off.
well that went straight out the window.
Started off with this.
You can see in the picture, the small plate i had cut to repair the flange where the bulkhead welds to the boot floor at the bottom.
So with that small plate welded in, it seemed to be going well until i decided to grind down some of the welds a bit further to neaten them right up.
long story short, i ground it too far on the fold and it ended up really thin so i cut out the thin section and welded in another bit.
Once it was finished and ground up i looked at it for a while and just wasn't happy so i made a cuppa and stood looking a bit longer.
It looked like a patchwork quilt and although it was strong and reasonably neat, i knew it was going to bug me so this happened
A bit drastic i know, especially as it would have been fine once it was sealed up and covered with the rear seat etc.
So after that major waste of time and set back i started to graft a replacement section. Started off with card transferred onto steel and then the folding began using the old piece as a guide.
Then a few slots on the curved parts to get the steel to go to the correct shape and a bit more folding and i had this
I then popped the arch tub in and tried the new piece in.
Not to far out for a first fit
And from inside the boot
still lots of trimming and shaping to do to get it perfect but i know i will be happy with it once it's done.
1 step forwards and 2 steps back.
Nobody got too far like that 
Cheers
Ben
On The Road
Posted 13 February 2015 - 07:16 PM
Mill Road Garage
Posted 13 February 2015 - 08:11 PM
I am slightly regretting re-doing it now.....
Mine is purple, but I have been told that's normal
Posted 13 February 2015 - 08:18 PM
I am slightly regretting re-doing it now.....
That's better than regretting not doing it
On The Road
Posted 13 February 2015 - 08:36 PM
Mill Road Garage
Posted 13 February 2015 - 08:39 PM
It won't be any stronger and it will never be seen, that's why i am regretting it because it's time wasted that could have been spent actually doing something constructive but hey ho. it's done now.
I like what you put Carlos and i agree.
I need to stop being so fussy!!!
A little bit little
Posted 13 February 2015 - 09:06 PM
Those are some mighty girlie lighters right there, Ben.
Mill Road Garage
Posted 14 February 2015 - 08:25 AM
Those are some mighty girlie lighters right there, Ben.
thankyou! They are lovely aint they
Mini Mad
Posted 14 February 2015 - 08:23 PM
Mill Road Garage
Posted 14 February 2015 - 08:28 PM
Hi ben,
Some great work...still slowly going through the thread...what where the wheels you used to clean the surface rust up after the flood?
Cheers,
Mark.
Hi Mark, Thanks for the compliments.
The wheels i use are called filament brushes and i buy them from eBay. They come in 2 different sizes as well as different types but i only use the smaller 75mm diameter ones.
They are here. http://www.ebay.co.u...=item27c84efa57
Cheers
Ben
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