464 replies to this topic

[gaspen]

In my very amateur view bolting the front panel to the teardrop mounts is useful to hold it in place,it cannot reliably fix its location as there are too many variables(subframe mounts accuracy of new panel etc)The sheetmetal is cosmetic,make it fit where it looks right then worry about bolting it up,after all some cars had teardrop mounts "shimmed" from the factory.Also regards heritage vs pattern if you have to cut the panel at all it may as well be the cheapest.Just my paupers DIY views.I understand entirely if others strive for perfection and I salute them.Steve..

 

My car don't have teardrops mounts as it is an Mk3

[sonscar]

Sorry I am not familiar with earlier models.So what does the front panel bolt to?Steve..

[gaspen]

Sorry I am not familiar with earlier models.So what does the front panel bolt to?Steve..

 

Simply there is no teardrop mount beetween the front panel and the front subframe. They are just bolted to each other with two 3/8 screws.

[Ben_O]

With the gaps near enough, I wanted to hold the wings firmly to the front panel and loose all the grips that were holding it together.

 

I added some tack welds dressing the panels together as I went

 

 

Then I could take off the front end as a complete piece

 

 

Then make a start getting the scuttle panel fitted permanently

 

First is to mark and make the cuts for the joins

 

 

And then clean up ready for fitting

 

 

Next up was to prep the scuttle for welding by cleaning back the e-coat from the join areas and apply zinc

 

 

And then once I was ready, I gave the top half of the bulkhead 2 coats of epoxy

 

 

And the same for the underside of the scuttle

 

 

And once dry, I fitted it

 

 

 

 

 

Then I put the front back on, played about with the fit a bit and it's now pretty much there

 

 

Now I can align and weld on the A panels

 

 

 

That side was done before I fitted welded in the scuttle but I did forget about the other side...

 

Here it is after the front went back on and clamped in place

 

 

Next is to weld it but I'm out of time today

 

Cheers

Ben

Edited by Ben_O, 30 October 2020 - 05:41 PM.

[gaspen]

Ben, one thing that I don't understand : you clean the welding surface, then apply zinc on it, and finally spray it with epoxy ? I learned that epoxy is better on bare metal or sanded E-coat. My experience with welding zinced area is that it will spatter and leave a poor plug weld. 

 

What do I know wrong ?

[Ben_O]

The epoxy is only applied to the non weld areas.

I apply the zinc to the weld areas first,mask off those areas and then apply the epoxy.

 

As for weld reactions with the zinc, I have had that in the past with some primers. The one I use now doesn't interfere at all with either mig welding or spot welding.

 

I think it's to do with the zinc quantity. The higher, the better 

Edited by Ben_O, 30 October 2020 - 07:51 PM.

[JAYSONIC 79 IOW]

Coming together now Ben great work

[steeley]

are you going to put a new skin on the drivers door. or try and repair the original

[Ben_O]

are you going to put a new skin on the drivers door. or try and repair the original

New door skins for both sides and frame repairs I'll be needed too.

Cheers

Ben

[Ben_O]

Been back to it the past few days but haven't had a chance to upload progress here.

 

Last time, I was going to weld on the left A panel

 

 

Next up was to blank off the Ariel hole

 

 

 

I also cut the front of the wing to even out the gap but only have an after photo for some reason

 

 

 

There is a bit of an issue here with the front panel. its got a chunk missing!

 

 

So I fixed that

 

 

And this isnt right despite the top of the wing and A panel being exactly where they need to be

 

 

So that was fixed too

 

 

With the front back off again, I went to fit the scuttle gussets but then couldn't find them. I realised that I hadn't ordered them so decided to make them instead.

 

 

 

And of course I did the other side.

 

Now the inner structure is completely done

 

 

So I coated it and the inside of the front end in epoxy

 

 

 

 

And then put the front back on for the last time

 

 

 

And then began the welding.

 

 

Not forgetting the straightener between the A panel and wing

 

Then after doing the same the other side, I did the wing to inner wing joins

 

 

 

Subframe back out

 

 

To do these bits

 

 

 

And the other side

 

 

I need to take the bonnet off for the next part and it wont be going back on until later so I used this opportunity to try the grille and see if it all fits properly

 

 

 

It's all pretty even but there is room for slight tweaking later.

 

Cheers

Ben

[Sam76]

??? this is car porn!

[gaspen]

Hello

 

Did you slice the front wing something like this ?

 

 hPTFtea.jpg   40.51K   5 downloads

[Ben_O]

Yes, that's right

 

Cheers

Ben 

[JXC Mini GT]

Great work Ben, it's a masterclass in replacing/repairing the front end of a mini.

[gaspen]

Yes, that's right

Cheers
Ben

That was my idea also. So this modification is approved ?