459 replies to this topic

[Daz1968]

Another little update today,

Spotwelded reinforcing plates where I could, I have ordered some longer arms for future panel work as it's a bit awkward with the 120mm arms that came with it.


I then plug welded the remaining area and linished smooth


Then I removed all paint from bulkhead while I had easy access and fitted floor and rear subframe, then spent a while checking dimensions, I also painted cold galvanising spray inside the sill areas to ensure they have a chance against future rust


I now have to clamp the tunnel to correct shape and plug weld it in position, the rest will be spot welded when I get the longer arms



The toe board needs a little more grinding before filling but welds are strong so happy with repair so far.

Looking forward to cutting out boot floor now

[Ben_O]

Lovely job. 

[Daz1968]

Got the plug welding done and ground down, then spot welded where I could, hopefully finish this and fit door steps next week

[minimissions]

Nice progress that's one big area coming together nicely :)

[Daz1968]

Done a little more today. I am going to take my time though and do it as best as I can,
I got my 350mm arms for spotwelder so could finish welding toeboard to floor. I had a few issues getting gap and pressure settings right but then I am new to spotwelding so still learning.



Then I marked out the doorstep for removal and added an extra brace from crossmember to ensure nothing moves.
I may have over done the spot welds but would rather have to many than have problems further down the line.



Then I trimmed the doorstep to size ready for welding, changed my welder to 0.6mm wire then ran out of time so will have to do some more next week



The fit of the m machine doorsteps is pretty decent though. My door gaps seem ok but think I will only weld to rear quarter and spot weld forward as far as the cross member, that should give me a bit of adjustment if needed when I fit the a panels, will get the m machine ones that include the door post I think.
I also signed up with boc this week as the hobby weld cylinders just don't last long enough and are expensive for refill,

[slidehammer]

Looking good as always. Interesting what you say about Hobby Weld Cylinders as I was thinking of doing the opposite and coming away from BOC and going for a Hobby Weld cylinder. Think I will stick with what I have and suffer the annual cylinder rental. If you are new to a spot welder one thing to watch out for is the metal needs to be really clean (far cleaner than with mig) This can be a real issue if you are welding new wings to existing inner wings for example you need to get the old metal really clean or the current doesn't flow. Not such an issue if the metal is all new. Get the metal clamped good and tight as well. Weld through primer aids current flow and protects. 

[Daz1968]

Thanks, I have used weld through primer on all areas and painted inside sills and doorsteps with cold galvanising spray,
As for the gas I get about 4x gas in a boc y cylinder for the same refill cost and the rental is less than £4 a month. This will easily be covered by reduced gas cost.
Hopefully get more done this week

[gadget555]

Nice work.

[minimissions]

Nice your cracking on well with this one thing i have noticed from the people on here that have done the one piece floors that one it place it looks like a mile stone and just looks so clean and tidy, cant wait to have one in my mk1 one day :)

[Daz1968]

Spent another couple of hours down the garage today and braved the cold

Cleaned the welder up and fitted my new boc bottle and regulator, amazed by how cheap regulators are managed to get a par weld one for £15, my one from hobbyweld bottle was horizontal fitting so thought best to get a new one



Got doorstep align correctly and got some spot welds on it



Then welded the joint to rear panel



Ground it down flush



Rear of repair showing full penetration, not sure if worth grinding this down



Couple of more pics





Then removed remnants of bin from other side and braced to cross member ready to cut it out. Had to add another bar to leave clearance for the door.



That's it for now, but hopefully get back on it soon.

[alchall]

I wouldn't grind down those welds in side the box section, you only risk thinning the metal and you'll never see them anyway, I would just clean up and paint for protection.

 

Looking good though, must be great being able to spot weld rather than have to mess around with plug welding!

[minimissions]

Loving this build some very nice tidy work... whats next to do?

[Daz1968]

Thanks for comments, next on my list is the drivers side doorstep, then a repair piece needs to be made for seat back panel, then I can cut out the boot floor,

[Daz1968]

Not done what I hoped today, but managed to prepare the boot floor for fitting, including making the pipe brackets and removing paint from anywhere requiring welding. I am not going to alter the section under rear seat as not going concourse and it really can't be seen by anyone except the most anal of early mini experts. I also can't use my existing floor section for fuel lines as it's to badly damaged, so have done similar to what most do I think

Welded a plate over hole and drilled for the fuel pipe and breather. Needs a little more flatting and filling but should be fine.
Flared the hole for fuel pipe as per original to prevent it damaging hose.



When the weldable zinc primer is dry I will spot weld and plug weld what I can to the boot floor before fitting.

[minimissions]

Nice work I take it the next step is to get that all Lined up with the car ? :)