591 replies to this topic

[colinf1]

that's a good idea I would never have thought the 3d print would be up to that, I've used it for my RC car parts over the years but generally mostly just the cosmetic parts, mechanical tend to break

like the pair of track rods I made for the TT01 that let go at full speed on a bend and rolled the car about 12 times lol

loving the sheet metal folding templates, do I spy a solid works theme there (same here)

Yes, that would be a Solidworks flat pattern for my template!

[colinf1]

Cut out the passenger front floor and the outer sill, actually found some good metal along the heelboard/subframe mounting bracket, so can get this wire brushed down and rust cured.



Hopefully get it all prep'd for welding in new floor on Saturday...

[colinf1]

Finished off the prep for welding passenger side floor pan in, last bit of the old floor was so corroded I couldn't make out the spotwelds so had to go at it with hammer and chisel. Eventually got it off, then cleaned up and rust treatment applied.

While waiting for that to work I made a start on the parcel shelf repair using a cut from the old drivers side inner wing...




Cut some metal to do the same the opposite side, just need to cut the hole and I'm going to try 3d print a form to roll the edge of the hole to match..



Then finally the welding marathon could begin on floor, about 90% done, small piece to be added each side of the tunnel, then get it plug weld to heel board...



Also got the drivers side floor welded to inner wing and toe board, so that side is pretty much finished apart from a few plug welds on crossmember and linishing it back...

[colinf1]

A few small jobs done this week, made a matching hole in the opposite side of the parcel shelf.



These are purely for strength, was easier to add stiffness this way than trying to form the groves..

Made a small section to go in the inner sill at the end of the front floor pan repair panel.



Ground back the welded to the 1st flute so I can get the outer sill welded in place then have a grind down all the underside Welds..

Got some 60mm pipe turned down to 58mm on the lathe today, then bored out the inside to 55ish for the fuel tank filler neck repair, need to add some positioning guides to the tank before cutting off the old neck to make sure it's in the right place.

Bit the bullet and ordered a full boot floor panel, battery box and quarter panel waist rails today...

[colinf1]

Got the passenger sill and brackets all welded on today,



Spot welded to the door step, then removed the bracing to allow the spot welder to get in to do step to inner sill..

Was hoping to finish up the inner wing to toe board but ran out of time.

[colinf1]

Got inner sill to door step spot welded, then a few patches that needed addressing on the passenger floor pan that the repair panel doesn't quite reach, crossmember plug welded and inner wing to toe board all welded and dressed back...not the prettiest of welding, but its not going to be seen..



Boot floor is en-route, hopefully the end of the welding is in sight too...

[colinf1]

Small repairs needed on rear seat panel, along the bottom fold to boot floor..



Cardboard template and cut from old quarter panel...



And offered up roughly in place...



Kept it below the seat belt mounts to avoid having to cut out the brackets.

Boot floor got delivered today 😆

[colinf1]

Lovely fresh metal...

[colinf1]

A few hours spent preparing the boot floor panel for welding, removing the e-coat, cleaning the earth strap captive nut and holder and painting the back of the quarter waist rails/liner retainer.



And nut spot welded into place while I had access



Next up is to cut out old waist rails and get the new ones in, then get some bracing for the boot floor removal.

[Ben_O]

Don't forget to modify the holes for the fuel lines if yiu are running original style lines

[colinf1]

Don't forget to modify the holes for the fuel lines if yiu are running original style lines

Cheers Ben, I already have that slot hole prep'd for welding in a new plate. Will probably just make a new piece to go in as there's surface rust everywhere on old boot floor.

Quick question Ben_O, there is a stiffener along the front edge of the seat base, do I need this or can I go without?

[Ben_O]

 

Don't forget to modify the holes for the fuel lines if yiu are running original style lines

Cheers Ben, I already have that slot hole prep'd for welding in a new plate. Will probably just make a new piece to go in as there's surface rust everywhere on old boot floor.

Quick question Ben_O, there is a stiffener along the front edge of the seat base, do I need this or can I go without?

 

It's best to use it if you have it as without, the seat base will bow between the centre brace when the rear seats are used.

 

Cheers

Ben 

[colinf1]

Fuel tank neck repaired over my lunch break...new piece of pipe, then the top pressing cut off and welded onto it, all grinded back ready for paint.

 

[colinf1]

Quarter panel waist rail welded in this evening, made a cardboard template of the side window just to be sure everything is in right place, thankfully it seems to be..



M-machine panel, so doesn't have the flange on the seat bulkhead side, so seam welded along the join. Passenger side one cut out and new one offered in. There was some rust that needed to be cut out on that side of the seat bulkhead, welded in a patch but had to hold off on linishing it back as it was getting a bit late to make noise.

[stuart bowes]

my tank has rot around the filler neck as well, is that common then

 

I was thinking ditch it and get a new one (of all the things it's best to just replace..) but have you seen the price, jeez

 

once you welded it up are you going to get it pressure tested or something, im thinking maybe if I do go down the repair route maybe it's one I should just get professionally done to be on the safe side.  but in theory there's no reason I can't just weld it myself though right