1498 replies to this topic

[Ben_O]

I dream of days this productive! 

 

The repair on the rear panel is great - I have that exact job to look forward to once I source a replacement.

Cheers

 

I should have sourced either a better one or a new one as this one does need alot of work but i like the challenge and it's perfect where it counts. Just that bumper seam to contend with.

[The Matt]

Yeah, always happens with me too haha. 1 can of primer for £8 in there... or 12 cans of better stuff for £30 on ebay.

Got a link?

Ben, your pics are really helping me with removing old inner and outer sills etc. So thank you! :)

[Ben_O]

 

Yeah, always happens with me too haha. 1 can of primer for £8 in there... or 12 cans of better stuff for £30 on ebay.

Got a link?

Ben, your pics are really helping me with removing old inner and outer sills etc. So thank you! :)

 

Excellent!

 

I shall be doing the other side very soon too

[James_eaton_thewholething]

Your updates are always good, shows that everything is possible and makes me know that all of my repairs are possible with just a bit of time and patience. I've got the boot hinge panel to replace soon and this has helped me see how it's done

[RossKnight]

 

Yeah, always happens with me too haha. 1 can of primer for £8 in there... or 12 cans of better stuff for £30 on ebay.

Got a link?
 

 

I've been using 'red oxide' (obviously no different to any other primer now because you can't get proper red oxide) purely because I started using a few cans I had at home, and then I wanted the rest to match.. But i'm pretty sure they do grey primer too.

 

http://www.ebay.co.u...=item43e01183f9

 

I used autotec acid etch primer back when I did my mini, and also paid about £30 for 12 cans. I'm not sure why I keep buying aerosols as I have a compressor and all the paint equipment.. oh well.

[Ben_O]

 

 

Yeah, always happens with me too haha. 1 can of primer for £8 in there... or 12 cans of better stuff for £30 on ebay.

Got a link?
 

 

I've been using 'red oxide' (obviously no different to any other primer now because you can't get proper red oxide) purely because I started using a few cans I had at home, and then I wanted the rest to match.. But i'm pretty sure they do grey primer too.

 

http://www.ebay.co.u...=item43e01183f9

 

I used autotec acid etch primer back when I did my mini, and also paid about £30 for 12 cans. I'm not sure why I keep buying aerosols as I have a compressor and all the paint equipment.. oh well.

 

Just to add, i always recommend using a zinc rich primer or weld thru primer on flanges prior to welding. It's also good in enclosed places like between the inner and outer sills for example.

 

It will help prevent rust forming in the seams

[Ben_O]

The rest of the boot floor is out and almost ready to take the new one.

 

Speaking of which, it has now been ordered along with some other goodies.

 

update to follow when i get time......

 

Ben

[Ben_O]

Back on with removing the remnants of the boot floor.

 

 

although the arch tub is being replaced, i need to keep it intact and in shape to line the new boot floor up to so i need to do it carefully.

 

Clean off the sealant to reveal the spot welds

 

 

First bit off

 

 

Bit more

 

 

Then drill the spot welds from the rear bulkhead to the boot floor

 

 

then split it and carefully peel it away

 

 

A bit more

 

 

And that's that chunk off

 

 

All gone

 

 

I need to keep this part as it has a reinforcer that runs along the front of the seat base so will need to go in after the new boot floor is fitted.

So i cut it off and put it to one side

 

 

Then i removed the remains of the side of the seat base where it welds to the companion bins

 

 

I couldn't get any flap discs so i got a pack of these 

 

 

Which are ok...

 

Then clean back the rust and remains of the spot welds

 

 

So that's it all gone

 

 

 

 

I also put some weld thru primer over the bare bits inside

 

 

 

I still have quite a bit of tidying up to do before the floor can go in but this little lot alone took hours and hours 

 

In addition, i need to make up a new bottom to the rear bulkhead as it is shot to bits.

 

More tomorrow......

[Rocket.]

Haven't looked at this in a while

 

Great work as always !

[Ben_O]

I got a bit more done today but not a scratch on what i had planned.

 

I need to get the lower rear bulkhead repaired before i can fit the new boot floor so i started by cutting out one of the rust ridden areas and made up a new piece.

 

here it is clamped in

 

 

And welded

 

 

Obviously once the repairs are finished, i will trim the repaired sections to the correct size. The reason for the oversized repairs is that i can weld the sections together on the edges further than it needs to be and then trim up to get a nice neat edge instead of blown edges. We all know what a pain it is welding to an edge.

I ground down the back side inside the boot but then whilst changing discs on the grinder, the spindle lock decided it didn't want to lock the spindle anymore...

 

so here is a very warm welcome to Grinder number 4

 

 

I also cleaned back the sealer from the floor to heelboard join

 

 

 

The reason i only did basically sod all is because i had to mess around taking the grinder back and waiting for the replacement and by the time that was sorted, i couldn't be bothered.

 

Ill try and get a full day tomorrow

 

Cheers

 

Ben

[Covert]

Looking good ben lots of progress since i lasted visited, keep the pics and updates coming .
All the best Mark.

[Ben_O]

Looking good ben lots of progress since i lasted visited, keep the pics and updates coming .
All the best Mark.

Cheers Mark.

[Ben_O]

All afternoon i have been slogging away and don't really have much to show for it.

 

The rear bulkhead repairs took much longer than anticipated due to the bottom being more corroded than i first thought.

 

Never mind...

 

First things first was to get this repair piece made

 

 

Which goes here.

 

 

Again, it is oversized so that it can be trimmed with the other part.

 

Here it is welded in

 

 

And then ground down and trimmed

 

 

the other side needed a bit too

 

Same process and here it is welded in

 

 

then i found this bit which i must have done when cutting the boot floor out. it's obviously from a cutting disc

 

 

So i made up a piece and welded that in

 

 

You can also see the other piece in that shot ground up and trimmed

 

 

next, i got on my back under the car and ground the welds back some underneath where they will be seen inside the boot. I left them slightly proud for strength but will need to revisit that area later down the line so that they are not visible on the finished car.

 

Here is a common thing on my shell and i'm sure many others

 

 

A slight rust trail which you might almost miss if you weren't really looking. My shell is covered in them, especially inside..

 

If you give it a very quick brush over, it's clear how far they spread

 

 

and another

 

 

 

And there are dozens more on the rear bulkhead alone. I shall end up stripping the whole panel back to make sure

 

anyway, the finished rear bulkhead repairs in some zinc spray

 

 

I can't believe how long it took and i had so much more planned but at least it;s a horrible job ticked off the list. it does me in keep clambering in and out of the shell

 

until tomorrow...

[James_eaton_thewholething]

Looks good Ben. It's definitely moving along now at a good pace cannot wait to see this finished

[Ben_O]

Looks good Ben. It's definitely moving along now at a good pace cannot wait to see this finished

Me too mate.

 

I just wish i wasn't having to rush it along currently because i am having to leave all the finishing until later where as i usually like to do it as i go.

 

It will be ok in the end though

 

Cheeers

 

Ben