1498 replies to this topic

[RossKnight]

Ben this is a smashing update considering you must have lost motivation and enthusiasm the other day due to thinking about getting rid.. Really impressed with all that work, got that a panel at a much better angle, and that's probably the best outer sill work I've seen for ages.

So glad you've got the instant garage thing as I've been looking into them as well so will be intrigued as to how you find it. Thought it would double up as a nice spray booth too.

Edited by RossKnight, 08 August 2015 - 10:24 AM.

[Ben_O]

Ben this is a smashing update considering you must have lost motivation and enthusiasm the other day due to thinking about getting rid.. Really impressed with all that work, got that a panel at a much better angle, and that's probably the best outer sill work I've seen for ages.

So glad you've got the instant garage thing as I've been looking into them as well so will be intrigued as to how you find it. Thought it would double up as a nice spray booth too.

Cheers Ross. The plan is to get as much done on it before the move.

 

I have just done another 7 hours on it today so there is another big update to come in a minute.

 

I am hoping the garage in a box will hold up in the weather. I want to get as many fly wheels and brake discs as i can and slide them over the base vertical poles to weigh it down.

i think it would make a great spray booth!

 

Ill let you know how i get on with it

 

Ben

[Carlos W]

 

Ben this is a smashing update considering you must have lost motivation and enthusiasm the other day due to thinking about getting rid.. Really impressed with all that work, got that a panel at a much better angle, and that's probably the best outer sill work I've seen for ages.

So glad you've got the instant garage thing as I've been looking into them as well so will be intrigued as to how you find it. Thought it would double up as a nice spray booth too.

Cheers Ross. The plan is to get as much done on it before the move.

 

I have just done another 7 hours on it today so there is another big update to come in a minute.

 

I am hoping the garage in a box will hold up in the weather. I want to get as many fly wheels and brake discs as i can and slide them over the base vertical poles to weigh it down.

i think it would make a great spray booth!

 

Ill let you know how i get on with it

 

Ben

 

 

Fly wheels? Where would you get them from?

[Ben_O]

Ok, today's update..

 

I started off by finishing off the grinding on the back edge of the outer sill

 

 

Then cleaned up this end ready for the heel board welding. I am going to seam weld the gap between the tabs too

 

 

Looks pretty neat. I shall seal it up with sealer when i get to that stage

 

 

Then i moved onto the front edge. I forgot to straighten the dodgy bit before fitting so i have had to open the gap up and slide a thin bolster in to act as a dolly to bash it straight

 

 

that'll do..

Then i welded it up

 

 

And ground it down and shaped it

 

 

So that's the sill finished

 

 

Next, I put the shell back up the right way to start cleaning the top side up. I just went over it with a poly wheel and am happy enough as the penetration dimples look enough like spot welds to me

 

 

 

I was going to then get on with the roof repairs but this bit has been bugging me for ever

 

 

There is a TON of filler in there so i picked up the grinder....

 

 

ooops. I guess ill be doing the back panel next then..

 

so i then did this

 

 

 

I wasn't quite as ham fisted as that, i did measure a few things first..

 

Anyway, I grabbed the new/old rear panel down off of the hooks

 

 

Then i cut off the excess and clamped it in place using the measurements i took.

 

 

not content with that, i thought i ought to find the rear lights

 

Guess which box they were in

 

 

Yup, you guessed right..

 

I also found some boot hinges that Carlos gave me ages ago but could only find the bolts and not the nuts so a quick walk round to the ironmongers (yes we still have them here) and brought these home.

 

 

they didn't have any imperial nuts for the bolts i had so i had to buy bolts too. Oh well, only 62p for 4 bolts, nuts and washers.

 

So in went the lamps and the bootlid just to double check

 

 

All looks well.

 

 

the other side is exactly the same gap wise

 

with it sat over the top, i thought about marking along the cut top and then just cutting it there

 

 

But then i decided to cut through both skins for more accuracy.

First you need to mark your cut line taking into consideration how much of the old panel you have and where it ends.

here is as good a place as any

 

 

 

then you need to support everything with clamps to stop it dropping off when you cut through

 

 

and then cut it

 

 

and the theory is, you should have a perfectly matched cut to weld the new to the old

 

Here are the bits of each that are not required

 

 

After doing the same to the other side gives you 2mm gaps to weld up

 

 

It was a bit tighter but i moved it down slightly on this side as the lamp bolts were binding very slightly on the mounts.

 

Then took the lot off

 

 

 

And cleaned up the edges inside and out.

 

 

 

Welding this up is much nicer with paint removed from both sides.

The bumper lip on this replacement back panel is in a much worse state than i remembered so it will all have to be replaced but i will make up one and weld it on once the boot floor is in place to aid lining up

 

Next up was to refit the back panel, lamps and bootlid to check alignment

 

 

 

 

Something went a bit wrong with the gap in the last picture so i just removed the lamp again and slit it again

 

I tacked both sides in place and then began fully welding the o/s and then gave up. So here is where i ended up

 

 

Reasonable gaps which can be fettled later on but certainly good enough for now. There is plenty of adjustment on the hinges

 

 

 

 

So until tomorrow....

[Ben_O]

 

 

Ben this is a smashing update considering you must have lost motivation and enthusiasm the other day due to thinking about getting rid.. Really impressed with all that work, got that a panel at a much better angle, and that's probably the best outer sill work I've seen for ages.

So glad you've got the instant garage thing as I've been looking into them as well so will be intrigued as to how you find it. Thought it would double up as a nice spray booth too.

Cheers Ross. The plan is to get as much done on it before the move.

 

I have just done another 7 hours on it today so there is another big update to come in a minute.

 

I am hoping the garage in a box will hold up in the weather. I want to get as many fly wheels and brake discs as i can and slide them over the base vertical poles to weigh it down.

i think it would make a great spray booth!

 

Ill let you know how i get on with it

 

Ben

 

 

Fly wheels? Where would you get them from?

 

pass

[Carlos W]

You missing the bottom section from the N/S light cluster mate?

 

And you seem to have forgotten to weld the bottom of the sill to the floor, there aren't any welds visible

[Ben_O]

You missing the bottom section from the N/S light cluster mate?

 

And you seem to have forgotten to weld the bottom of the sill to the floor, there aren't any welds visible

Yes, i think it got lobbed. i think you looked in your stash for one but didn't have one.

 

And...oops, ill have to go back to that then

[Carlos W]

I thought I saw one today. I'll have a look in a bit

[Ben_O]

Oh and at some point during the madness,i chopped a bit more boot floor out

 

 

The rust is slowly fading

[Ben_O]

I thought I saw one today. I'll have a look in a bit

Wonderful!

 

Cheers

[Ben_O]

So the shopping list is now 

Rear subframe fitting kit and trunnions

Boot floor

o/s inner arch

n/s rear lower seatbelt mount

Rear valance

rear valance closers

Rear subframe mount stiffeners

 

i think..

[Carlos W]

 

I thought I saw one today. I'll have a look in a bit

Wonderful!

 

Cheers

 

 

2 apparently.

 

They're with your brake pipes

[Ben_O]

 

 

I thought I saw one today. I'll have a look in a bit

Wonderful!

 

Cheers

 

 

2 apparently.

 

They're with your brake pipes

 

Fantastic!

 

I have a couple of lamps here that you gave me before. One is complete and one is missing the lens so ill make up a nice set with what i have

[Carlos W]

 

 

 

I thought I saw one today. I'll have a look in a bit

Wonderful!

 

Cheers

 

 

2 apparently.

 

They're with your brake pipes

 

Fantastic!

 

I have a couple of lamps here that you gave me before. One is complete and one is missing the lens so ill make up a nice set with what i have

 

 

I need to re-discover those wheel nut covers too. I put them in something........

[1590gilbert]

Hi ben, just reading through n you say you will need some welding curtains?

Well i sell heavy duty pvc (bouncy castle material) which is flame retardant which i have tried n tested with the grinder and sold for welding curtains. Let me know if its something your interested in. Cheers