87 replies to this topic

[alex-95]

 

Excellent work, what are you using to grind down the welds?

Thanks! I used flap discs that I got from ebay on the grinder, the ones I bought were p40 as far as I can remember. Heres the ebay link: http://www.ebay.co.uk/itm/201191699103

 

Cheers, I've got them, I'll have to try harder to get mine looking like yours

[Carlos W]

You weren't tempted to put a full inner wing on?

The area behind the shock mount is double thickness

[Ben_O]

 

 

Excellent work, what are you using to grind down the welds?

Thanks! I used flap discs that I got from ebay on the grinder, the ones I bought were p40 as far as I can remember. Heres the ebay link: http://www.ebay.co.uk/itm/201191699103

 

Cheers, I've got them, I'll have to try harder to get mine looking like yours

 

Grind down the bulk with a stone and then finish off with a flap disc making sure the disc stays in contact with only the weld right until it's flush and then tickle the area lightly to blend

[Adam1275]

You weren't tempted to put a full inner wing on?

The area behind the shock mount is double thickness

I was tempted by a full inner wing but the price put me off and the worst part of the wing was the flitch panel the rest wasn't too bad except behind the shock mounts  

 

As for the shock mount I cut out the two separate pieces of metal and replaced them with one piece of 2mm steel. This should stop the water getting down between the two pieces and rotting this panel out 

[Carlos W]

You weren't tempted to put a full inner wing on?
The area behind the shock mount is double thickness

I was tempted by a full inner wing but the price put me off and the worst part of the wing was the flitch panel the rest wasn't too bad except behind the shock mounts  
 
As for the shock mount I cut out the two separate pieces of metal and replaced them with one piece of 2mm steel. This should stop the water getting down between the two pieces and rotting this panel out

I think the main issue is the shock mounted wasn't painted before it was put on the car. With salt, water and road dirt it rots

[Adam1275]

 

 

You weren't tempted to put a full inner wing on?
The area behind the shock mount is double thickness

I was tempted by a full inner wing but the price put me off and the worst part of the wing was the flitch panel the rest wasn't too bad except behind the shock mounts  
 
As for the shock mount I cut out the two separate pieces of metal and replaced them with one piece of 2mm steel. This should stop the water getting down between the two pieces and rotting this panel out

I think the main issue is the shock mounted wasn't painted before it was put on the car. With salt, water and road dirt it rots

 

Yea that could be the problem I will make sure to get the car painted with the shock mounts off. 

[Carlos W]

You weren't tempted to put a full inner wing on?
The area behind the shock mount is double thickness

I was tempted by a full inner wing but the price put me off and the worst part of the wing was the flitch panel the rest wasn't too bad except behind the shock mounts  
 
As for the shock mount I cut out the two separate pieces of metal and replaced them with one piece of 2mm steel. This should stop the water getting down between the two pieces and rotting this panel out

I think the main issue is the shock mounted wasn't painted before it was put on the car. With salt, water and road dirt it rots

Yea that could be the problem I will make sure to get the car painted with the shock mounts off.

easy enough to paint under there, and paint the shock mounts off the car

[Adam1275]

Well it's been a long time since this was updated, so here goes...

 

picking up from the last update started by putting on the passenger sill 

 

 

 

plug welded to the doorstep:

 

Then rolled over to plug weld to the floor:

 

 

and ground down:

 

 

Next thing to change was the boot floor and the rear arches. The old boot floor was completely gone: 

 

 

 

 

 

Started by roughly cutting out the main area of the boot floor:

 

 

 

 

 

Here's it's replacement Heritage boot floor:

 

Since both the rear arches were being replaced as well I decided to weld the arches to the floor to replace as one. I firstly made a jig to get a position for the old rear aches before I cut anything out. Here's them trial fitted:

 

Then zinc primer applied to the seams:

 

The arch drilled for the plug welds and zinc primer applied:

 

and welded on:

 

 

[Adam1275]

and the same on the other side:

 

 

 

 

 

Then trial fitted into the floor:

 

and back out again to take back to bare metal where it will be welded and zinc primer applied:

 

and in for the final time. The rear subframe was put back in to make sure it was in the right place and the jig to check the rear arches were in the right place was used to make sure the floor was in the right place before it was welded. 

 

Welded to the companion bins:

 

The bottom of the back seat was badly rotted. I could have repaired it but decided to replace the rear bulkhead to make things easier:

 

 

Along with a new set of rear seat belt mountings:

 

 

 

 

 

Welded the tank captive nut to the rear bulkhead:

 

Then welded the seatbelt mountings to the rear bulkhead:

 

 

While I had room I welded the support brackets to the rear arches: 

 

 

Also welded in the support brackets at the rear of the wheel arches:

 

 

 

Then set about welding in the rear bulkhead:

 

[Adam1275]

and ground down:

 

 

 

Next up was the parcel shelf and top rear seatbelt mounting panels. I'm thinking the rear screen was leaking in the past with the amount of rust in one corner. Someone had also tried to drill out for speakers. 

 

 

 

 

 

and the new Heritage parcel shelf: 

 

Trial fitted:

 

 

Welded to the rear bulkhead:

 

 

Welded in the tank bracket on the boot floor:

 

Next up was the rear panel. Here is it's replacement: 

 

 

Trial Fitted: 

 

and with the boot lid. The gaps will need some work but that's a challenge for another day: 

 

Zinc primed: 

 

The old one removed: 

 

 

and welded: 

 

 

[Adam1275]

 

 

 

Another update to come tomorrow have to get the rest of the photos uploaded.

[panky]

I'm out of breath reading that - great work

[jamesquintin]

Wow, you've pretty much done what I've done but 1,000 times quicker!

[NZMini1275]

Now that's how to post an update
Great looking reoairs

[Adam1275]

Thanks for your comments guys! 

 

I realised I missed the passenger side rear quarter panel replacement so here it is.

 

Trial fitting the new Heritage panel: 

 

 

Painting in behind before it gets welded:

 

 

Then welded on: 

 

 

 

 

Then set to work about removing & replacing the toe board. The old one was rotting along the seam with the floor and the rust had been plated over before in the past so the only option was to remove the whole thing and do it properly. I had to do a repair at the bottom of the bulkhead as well as there was a hole starting to form. 

 

 

 

Probably went slightly overboard with the plug weld holes... 

 

New panel trial fitted: 

 

Ended up taking the inside of the lower bulkhead back to bare metal and treating it with deox gel before priming it

 

 

 

 

 

Then primed the panel before welding 

 

Also I missed from yesterdays update that I filled in the MPI hole for the fuel pipes in the boot floor. I still have to drill out the holes yet. 

 

Next on the list was repairing and re-skinning the two doors. Here is the passenger side door taken back to bare metal inside. The bottom was badly pitted so was cut out and replaced:

 

 

 

 

The inside of the door painted and tiger seal applied to the seam along the bottom: