684 replies to this topic

[Ben_O]

Chop Chop indeed.

 

With no points of reference how on earth do you start positioning and welding the initial panels so that all the subsequent panels line up and fit?

Hi Mike.

 

I did start to type up what I had planned but it was getting very in depth and then it dawned on me that i will be writing about it as I do it so if you want to keep an eye out, you will see how I do it.

Cheers

Ben

[MikeRotherham]

Why didn't I think of that?

Edited by MikeRotherham, 04 December 2019 - 09:51 PM.

[Ben_O]

Back on with splitting/repairing of the front panel after yet more days off sick..

 

Last time, I had this to clean 

 

 

 

 

The other side was a bit worse as the bit I need to keep was blown

 

 

I cut it all away and rebuilt the edge instead

 

 

 

 

And that's the front panel repaired and ready to fit

 

 

Next, Ill be bracing up and removing the bulkhead

 

Cheers

Ben

[Jase]

Ben, given the time you have had to spend on this wouldn't it have been cheaper and easier to buy a replacement panel?

[Ben_O]

Ben, given the time you have had to spend on this wouldn't it have been cheaper and easier to buy a replacement panel?

The clubman front panel pieces are pretty expensive and as this was in good condition, it made sense to reuse it. The repairs took less than 2 hours.
Cheers
Ben

Edited by Ben_O, 06 December 2019 - 10:22 AM.

[Bdshim]

Nice job ?

[Ben_O]

Onwards and upwards.

 

Bracing installed

 

 

This probably isn't strictly necessary on a good strong shell like this but I would like to cut out and replace the upper half of the A post boxing panel both sides once the bulkhead is out so it wouldn't hurt to be cautious.

 

5 cuts later, and it's out

 

 

Next up, aforementioned A post repairs.

 

Cheers

Ben

[eric67]

Crikey! This is scary stuff but good to see the car getting the expert treatment it needs.

[JXC Mini GT]

Excellent repair on the front panel Ben, 5 cuts and now the front is totally naked.  

[Ben_O]

Cheers guys :)

[cookie4343]

Excellent work Ben. Your a very brave man cutting that lot out.

[Ben_O]

Can't do all that much right now on this as the panels won't be here until Wednesday.

 

I have now however repaired the upper sections of boxing panels on the A posts. I had already replaced the lower sections 3 years ago but the top sections weren't very accessible and the plan had always been to revisit this. With the bulkhead and dash rails out of the way, it was clear to see that they were in a pretty poor state.

 

 

Once I had cut the bad bit out, I made a card template

 

 

Transferred onto steel

 

 

And clamped to the car

 

 

And then welded into place

 

 

Then I repeated the same on the other side

 

 

 

 

I then remembered that I have a top dash rail in stock and as thats the first panel that needs to be fitted, I borrowed that and got it fitted.

 

Its not difficult to fit but needs to be in the correct place so best thing is to get it offered up

 

 

It should sit flush with the fold in the bottom of the windscreen boxing panel so I put a tack weld in the front edge both sides

 

 

The pics are a bit jumbled up between sides so I have used pictures from both sides to tell the story..

 

With both sides tacked, I need to get the height correct. The windscreen height measurement on most shells is around 410mm in the centre and each side above the outer screen vent screw hole so I added a copper backing plate behind this join

 

 

And check the measurement for this side

 

 

418mm....

 

With it clamped , I can now tap the dash rail up from where its clamped to get the desired measurement.

When I measured this car prior to cutting, the measurement was 412mm and another shell I have here is 410mm so I went for 411

 

 

Now I can weld that join up

 

 

And that holds the height correctly.

 

I did the same the other side and then ground flush

 

 

Then welded up the seam between the dash rail ends and the screen boxing panel

 

 

That needs shaping correctly with the die grinder but the bracing is in the way currently.

 

Last thing was to spot weld the end tabs to the A post boxing panel

 

 

And that is now in exactly the correct position with consistent 411mm measurements across. 

 

Cheers

Ben

[tankertanker]

Breathtaking stuff , behind the sofa for this one from now on ....

Absolutely top work

[Ben_O]

We are expecting the new engine to turn up painted green based on the photographs on the suppliers website and John the owner would like it black so I will be refinishing it accordingly.

The head will also need cleaning back and repainting so I thought whilst I wait for the order to arrive, ill degrese the existing engine and get the head off.

 

 

 

Turns out it used to have a colour coded engine.....

 

Anyhoo, head off

 

 

I had the head checked before going any further and there are some discrepancies so a skim will be wise.

 

More tomorrow

 

Cheers

Ben 

[Ben Rose]

Crikey!  Amazing work Ben.