1498 replies to this topic

[CBJ805T]

Looking good Ben!

 

this is a job I'm going to have to tackle at some point. I was just wondering how you ensure you've got the inner wing level etc to ensure that it'll match up with the other side when the outer wings / front panel go on - if that makes sense. 

 

Cheers Chris

[Ben_O]

Looking good Ben!

 

this is a job I'm going to have to tackle at some point. I was just wondering how you ensure you've got the inner wing level etc to ensure that it'll match up with the other side when the outer wings / front panel go on - if that makes sense. 

 

Cheers Chris

Hi mate.

 

It is reasonable straightforward. The main problems i have had were getting the inner wing to actually fit in the hole.

 

The height of the inner wing can be determined simply by lining up the holes for the top shock mount with those on the end of the crossmember. That will sort the height at the front out.

 

The height of the flitch area can be determined by lining up the door hinge holes, especially if you are retaining the original hinge panel. It is also worth mentioning that the top of the lip where the A panel folds round sits tight up against the external seam for the windscreen frame.

 

And of course the final way to tell is to trial fit the scuttle, wings and bonnet as i did a few pages back. I guessed the position of my inner wing based on the way it fitted to the surrounding panels and it worked out fine with even panel gaps either side and nice and even across the top.

 

Hope that helps.

 

Ben

[Ben_O]

Pathetic update today. I just wasn't in the mood after i got my tools out and started.

 

First up, attend to this gap

 

 

Made up a small piece to go in

 

 

And then welded up and ground down

 

 

Next job was to fit the stiffener which meant fitting it along with the inner wing again to get it squared up and then i scribed onto the stiffener the correct position before taking it all off again.

 

Here it is in position and drilled ready for plug welding

 

 

Then welded and ground down

 

 

Followed by a splash of zinc

 

 

 

 

Then time to check all the panel alignment again by clamping the inner wing on AGAIN... yawn

 

Shock mount holes all lined up nicely

 

 

The same goes for the hinge holes

 

 

All clamped perfectly in place

 

 

 

And then on with the door and apex panel to check alignment again

 

I wont bore you with more panel gap pictures, just imagine nice even gaps

 

I was having trouble getting the bottom front edge of the door to sit nice with the A panel, it seemed to sit back a bit too far so i belted it with a hammer and some filler fell off!

But it now fits much better without the lump of filler

 

 

It doesn't look great in that picture but in reality, it's pretty much spot on.

 

Then i got bored.......

[Hendred]

You did well to do what you did when not being in the mood!  I just go and chop logs or something when I can't be bothered lol

[Ben_O]

A bit more done today.

 

started by drilling all the holes in preparation for plug welding the inner wing on

 

 

 

Then i linished the burrs and removed the paint from the areas that are to be welded

 

 

And applied some Zinc primer

 

 

 

Here it is clamped back into position. There was no need to refit the door, Apex panel and Wing to check panel gaps as i can now position the inner wing in exactly the same place everytime i put it in so that saved some time.

 

 

The first few of many plug welds.

 

 

At this point, i only plugged up a select few of the holes to keep the inner wing into position because i had a bit of a problem to sort out.

This meant tipping the shell back on it's side to reveal the problem.

 

 

It's not brilliantly clear but there is a half inch gap between the bottom of the inner wing and the floor/inner sill. The toe board fits perfectly to the inner wing and the inner wing is definitely at the correct height and fits well everywhere else so i don't know how this has happened??

My plan A was to use a block of wood and a club hammer to bring the floor down to meet it but this didn't work so i had to take Plan B

 

 

Thats right, i had to cut a lump out of my £100 panel.

 

anyway, needs must and all that so i repositioned it for a better fit

 

 

Then scribed it, cut it and laid it back into position

 

 

 

Tacked it in

 

 

And readjusted another piece which you can see towards the bottom of this picture

 

 

Then welded it up fully

 

 

And ground it back

 

 

Once it was all sorted, i ended up with an odd shaped part where it wraps under the floor so i have made up a piece to go in. Not strictly needed but i felt it would look neater

 

 

That will be welded in tomorrow along with the rest of the plug welds on the inner wing. Other than that, i need to trim the bottom of the inner wing where it meets the front of the outer sill as the profile is wrong.

 

Cheers

 

Ben

[Carlos W]

Excellent work as always mate.

When is the rest of the front end going on?

[Jared Mk3]

The attention to detail on this build is superb.

[SAL 821X]

Fantastic fabrication as ever Ben.

[Ben_O]

Excellent work as always mate.

When is the rest of the front end going on?

Cheers Carl

 

The rest of the front end will go on last once the rest of the body is done.

Once the inner wing is complete, the a panel will go on then i will move back to doing the quarter panel and outer sill etc.

[Ben_O]

The attention to detail on this build is superb.

Thanks Mate

[Ben_O]

Fantastic fabrication as ever Ben.

Cheers Mate.

 

I just can't understand why that bit didn't fit right?? Oh well, i guess these things happen

 

Ben

[Ben_O]

Right, yesterdays progress.

 

First up, i needed to go and buy yet another grinder as the crappy silverline one packed up for the second time. I bought an Einhell one which is the best grinder i have ever owned!

 

 

The motor is so smooth and it really is much quieter in operation than the others i have owned. I would recommend it to anyone.

 

So i started by plug welding the bottom of the inner wing to the floor and inner sill

 

 

 

Ground those down

 

 

 

 

Back on it's belly, i cleaned the inside up

 

 

And made up some filler pieces

 

 

Then welded them and ground them down

 

 

I did run out of time so ill tidy them some more today and also get the rest of the plug welding done on the inner wing.

 

Cheers

 

Ben

[Hendred]

Looking so good Ben, it actually motivates me reading your thread to keep going with mine so thank you!

 

[minimissions]

Just looked at a small part of thi build and wow what tidy work I love the attention to detail that you have taken the time to do. Top work, going to go back and have a proper look through now ;)

[myredmini]

All these small touches make a big difference!  top work Ben.