156 replies to this topic

[minimikej]

Got the new bulkhead trial fitted this afternoon. I was worried that no way were the gaps going to close, but when I managed to get some bolts through the steering rack jigs it pulled together without any problems.

 

2020-05-11_05-45-43 by Mike Jackson, on Flickr

 

2020-05-11_05-45-59 by Mike Jackson, on Flickr

 

And here you can just about make out the subframe mounting holes clearing nicely. There's a bolt through the lower offside.
2020-05-11_05-46-30 by Mike Jackson, on Flickr

It looks like I might be able to get the spot welder in to join the parcel shelf to the bulkhead if I rotate the electrodes to meet slightly off centre.

Now I need to remove it all again and strip back the e-coating where the welding will be done.

[KTS]

that's a decent step forward.

 

oddly enough i was working on the back subframe mounts of mine the other day and wondered why the floor panel had a couple of cutouts where it meets the toeboard.  now i know !

[simpsonsclassics]

Big step forward for sure, will it still retain the twin bolt subframe set mike? i see m-machine now sell the little conversion panels 

 

So nice seeing some fresh steel up front

[minimikej]

Big step forward for sure, will it still retain the twin bolt subframe set mike? i see m-machine now sell the little conversion panels 

 

So nice seeing some fresh steel up front

Ah what??! I missed that!

Yes, it's keeping the twin bolt subframe, I've started spot welding the bulkhead in, will post some pics in a bit. Last bits of grot starting to disappear at last

[Bdshim]

grreeaatt project really coming together, look forward to the updates

[minimikej]

So, in between phone calls trying to land a new job, been proper busy in the garage.

 

New top dash rail installed and spot welded in

2020-05-19_06-43-50 by Mike Jackson, on Flickr

Inner wings offered up and clamped in place. Bit of a struggle there to be honest. The profile of the flitch panel where the bend is does not match the profile of the parcel shelf I left in situ. That's going to take quite some persuasion.

2020-05-19_06-44-11 by Mike Jackson, on Flickr

 

 

2020-05-19_06-44-53 by Mike Jackson, on Flickr

Next job is to attach the inner wings to the bulkhead and the floor pans. Then I will worry about the A-posts and how on earth I can swap them out whilst leaving the jig intact.

 

Cheers

[simpsonsclassics]

 

Big step forward for sure, will it still retain the twin bolt subframe set mike? i see m-machine now sell the little conversion panels 

 

So nice seeing some fresh steel up front

Ah what??! I missed that!

Yes, it's keeping the twin bolt subframe, I've started spot welding the bulkhead in, will post some pics in a bit. Last bits of grot starting to disappear at last

 

 

 

Big step forward for sure, will it still retain the twin bolt subframe set mike? i see m-machine now sell the little conversion panels 

 

So nice seeing some fresh steel up front

Ah what??! I missed that!

Yes, it's keeping the twin bolt subframe, I've started spot welding the bulkhead in, will post some pics in a bit. Last bits of grot starting to disappear at last

 

She is really coming together glad you keeping the twin bolt frame. Cant wait to see this done..

[minimikej]

Making the absolute most of the last of the fine weather today.

Repairs to the parcel shelf front edge, inner wings are in and partly welded!

 

Parcel shelf n/s repair:

2020-06-02_06-30-15 by Mike Jackson, on Flickr

 

Offside more rotten:
2020-06-02_06-30-32 by Mike Jackson, on Flickr

 

 

Chopped rotten end off and rolled it over some sheet steel to make this:

2020-06-02_06-31-04 by Mike Jackson, on Flickr

 

Old and new:
2020-06-02_06-31-20 by Mike Jackson, on Flickr

 

Welded in:

2020-06-02_06-32-38 by Mike Jackson, on Flickr

 

Back to this old chestnut. The massive difference between inner wing profiles of the Heritage panel and the original A post:

2020-06-02_06-31-50 by Mike Jackson, on Flickr

 

Getting some spot welds in:

2020-06-02_06-32-06 by Mike Jackson, on Flickr

 

Welded some threaded bar to the framework to pull the flitch panel inwards and close up to the parcel shelf:

2020-06-02_06-32-23 by Mike Jackson, on Flickr

 

Got the shell level; taken across the rear window apertures:

2020-06-02_06-32-51 by Mike Jackson, on Flickr

 

Success! Bulkhead crossmember also level:
2020-06-02_06-33-14 by Mike Jackson, on Flickr

 

Tidyup and rest:

2020-06-02_06-33-27 by Mike Jackson, on Flickr

 

 

 

[minimikej]

Weather been too awful to do much today, but I've located the n/s door and offered it up.

 

Gaps are good on the front rail:

2020-06-03_06-42-45 by Mike Jackson, on Flickr

And the top rail:

2020-06-03_06-43-01 by Mike Jackson, on Flickr

And the rear edge:

2020-06-03_06-43-12 by Mike Jackson, on Flickr

But zero gap on the front edge! Here you can just about make out the remains of the original A post:

2020-06-03_06-43-34 by Mike Jackson, on Flickr

 

 

Both doors have always been wedged in their frames under my ownership. Paint worn off along the entire rear edges of both doors. Can't understand why though; the A posts do not look like they have been repaired in the past. Anyway, onto the next issue.

 

I mentioned previously the poor fit of the Heritage n/s inner wing. Had the exact same issues on my previous mk1 project (see here: http://www.theminifo...-rebuild/page-7)

 

Tried to get some measurements to demonstrate, to discount any alignment issues on my behalf.

 

Here is the eyeball measurement between the shoulder pressed into the inner wing, the shiny horizontal line at the top of the tape measure in the photo, and the top dimple where the inner A panel would nestle up:

2020-06-03_06-44-18 by Mike Jackson, on Flickr

5 Inches, give or take.

 

Now compare to the o/s Heritage inner wing:

2020-06-03_06-44-31 by Mike Jackson, on Flickr

4 inches!

 

Ties up with the awful profile at the top.

 

I can't be the only one experiencing this problem, what do other people do please? I'm minded to cut the edge right off, shift it upwards, and re-weld it!

Edited by minimikej, 03 June 2020 - 06:08 PM.

[Homersimpson]

Being level like that is almost certainly better than when it was made

[minimikej]

Time to start on the A posts. First job, getting the sheared studs out of the door hinges. 3 out of 4 came out.

 

2020-06-05_07-14-07 by Mike Jackson, on Flickr

Mock up the outer A panel and wing. I used joiners biscuits to provide a uniform 5mm gap aroud the door:

2020-06-05_07-14-21 by Mike Jackson, on Flickr

Then the fun starts. It's a 4 dimensional problem. Everything has to be replaced in the A post assembly but you can't do it all at once or the gaps will be awful. As I learned on the last project.

So, start with what's most visible, outer A panel. Tacked in place, but only temporarily to enable the box section of the A post to be assembled in the right place:
2020-06-05_07-14-51 by Mike Jackson, on Flickr

 

With door clamped and spaced with the biscuits:

2020-06-05_07-15-03 by Mike Jackson, on Flickr

Next I chopped out the rusty part of the A post that would house the courtesy light switch if fitted, and squeezed in the new one...

2020-06-05_07-15-13 by Mike Jackson, on Flickr

 

...and tacked that in place too:

2020-06-05_07-15-43 by Mike Jackson, on Flickr

The next job will be to slice out the badly pressed section of the inner wing, attach it to the inner A panel with tech screws, and refit both as a pair to the outer A panel and clamp tight through the hinge bolt holes. And then tack the cutting into its new location. This will hopefully ensure a snug mating between the outer and inner A panels and avoid the nightmare I created for myself on the blue mk1.

Quick look at the door, doesn't look too bad at first glance:
2020-06-05_07-15-54 by Mike Jackson, on Flickr

However, there's a really sharp dent / crease on the inside. This is repeated down the n/s rear quarter too:
2020-06-05_07-16-07 by Mike Jackson, on Flickr

Here you can see where the door was catching in the frame after whatever previous repairs were done in this area:
2020-06-05_07-16-18 by Mike Jackson, on Flickr

2020-06-05_07-16-27 by Mike Jackson, on Flickr

Edited by minimikej, 05 June 2020 - 06:47 PM.

[minimikej]

Plan into action then. First, cut out the poor A panel mount section:

 

2020-06-07_09-56-04 by Mike Jackson, on Flickr

 

Then, seat it nicely against the inner A panel and secure in place with a tech screw:

 

2020-06-07_10-02-30 by Mike Jackson, on Flickr

 

2020-06-07_10-02-39 by Mike Jackson, on Flickr

 

Then, offer it up to the outer A panel, and clamp in place with all the holes lined up and that

 

2020-06-07_10-02-49 by Mike Jackson, on Flickr

Tack it in place with some very wide tacks :)

2020-06-07_10-02-58 by Mike Jackson, on Flickr

 

And finally the reveal - seems to sit flush with the lower A post panel now. Going to have to let in a fillet though to weld it properly unfortunately.

 

2020-06-07_10-03-07 by Mike Jackson, on Flickr

 

 

Money shot:

2020-06-07_09-58-20 by Mike Jackson, on Flickr

 

 

[Standeman]

Really great stuff there minimike.....loving the detail. Really helping me visualize whats coming up for mine in the next few months - Thanks! Looking forward to the progress!!

[g111mds]

Really great progress,

[ed4ran]

Great work going on! Love that you are making the effort to correct all the little panel issues! ??