464 replies to this topic

[Shep76S]

Do we get to see the Land Rover repairs as well?

[Ben_O]

Do we get to see the Land Rover repairs as well?

I can always put some photos up on the mill road thread if you would like.

 

Cheers

Ben

[wingnut]

Very neat work as ever Ben.Yes please to the Land Rover pics , what year is it?

[simonaoz]

Hi Ben, quick question; when you spot weld do you clean both flanges to bare metal or do you leave them coated in weld through primer?

[Ben_O]

Very neat work as ever Ben.Yes please to the Land Rover pics , what year is it?

Thanks.

The land rover is nothing interesting. It's a 2000's defender.

 

Hi Ben, quick question; when you spot weld do you clean both flanges to bare metal or do you leave them coated in weld through primer?

Yes, I always clean back to bare metal and use a weld thru primer between the pieces to be welded.

Cheers

Ben

[Ben_O]

Back to the advantage this afternoon.

 

I started by plug welding the front of the floor to the toe board

 

 

And then made a start on the right hand step.

 

 

 

With the old one cut away, I could clamp on the  new one to check for fit.

 

 

These magnum step panels aren't the greatest in finish but they fit well and can be tidied up nicely.

 

With the door back on, I can check the fit

 

 

 

A frilly door is not the greatest datum but it's good enough to check the gaps.

 

The next step is to mark the join line with the quarter panel.

 

 

The black line is the edge of the new panel and the pencil line is 10mm below. 

This is where I will cut the quarter panel.

 

Once I cut along the pencil line, I joggled the edge up to the black line and cleaned back

 

 

Now the new piece can sit in flush and the joggled edge will add rigidity to minimise distortion.

 

 

With the cutting in complete, I can clean up and prep the areas.

 

 

I just need to cut in the a post up front now and it's ready to fit.

 

Cheers

Ben

[Ben_O]

I decided rather than fit the step and quarter bottom as one piece and loose the little seam between, I cut it up and modified the two pieces to retain the factory seam.

 

 

 

Before I weld it all on, I painted inside the cavity and the insides of the new pieces with epoxy.

 

 

 

Next, I clamped the step into place, measured the height of the step and then tacked the joins at the A and B posts

 

 

And then once I had trial fitted the door, I spot welded the seams and welded up the joins fully

 

 

 

Just the quarter bottom to go now.

 

Cheers

Ben

[Ben_O]

Here is the new quarter bottom clamped and tacked in place

 

 

And then spot welded 

 

 

And then after slowly welding up the join.

 

 

Cheers

Ben

[Ben_O]

 

 

On to the other side now.

 

 

I'm taking a different approach this side as it needs an a post too

 

 

A panel removed

 

 

And tomorrow, I shall remove the outer a post and repair the inner ready for the new bits.

 

Cheers

Ben

[floormanager]

It's such a good job I cannot do this.  I'd be buying all the sheds on Ebay to do up!!  Well jealous Ben

[Ben_O]

First job today was to remove the outer A post.

 

Just a few spot welds to drill and a cut at the top and its off

 

 

It's actually pretty clean in here which is surprising looking at the state of the outer panel.

 

I removed the inner hinge frame piece anyway so that I could check it and clean the back edge if needs be. It's actually really clean

 

 

 

There are a few areas on the boxing panel that need repairing but not too much

 

The worst of the rust on the frame piece was around the check strap bracket so I blasted it

 

 

 And that's ready to go back on.

 

Here is the boxing panel and flitch cleaned up

 

 

The first of the repair pieces for the boxing plate made and ready to weld

 

 

And the repairs completed

 

 

Hinge frame clamped back in

 

 

And then welded

 

 

I'm waiting for an outer A post to arrive so I started getting the back end prepared

 

 

 

And ready for the new bits

 

 

As soon as the A post arrives, ill get that finished off

 

Cheers

Ben

[Ben_O]

Not much time on the advantage today but I got one repair done.

 

 

Quite an awkward bugger.

 

 

The section with the hole sits under the outer B post so that needs to be cut off carefully

 

 

And then I could remove the holes section

 

 

And make up a new piece

 

 

Weld it in

 

 

And then carefully graft the previously removed outer back on, grind up and repair complete

 

[Sam76]

Utterly amazing work Ben! You’re an inspiration- can’t wait to get my hands on a rusty wreck ( just need to find one lol)

[JAYSONIC 79 IOW]

Great work Ben

[Gilles1000]

ahhh thats makes the difficult repairs look very easy!!

I'm afraid to start on the A post, I have quite the same rust hole on the door surround. But I first have to move my way frome the last repairs at the back and then go on up to the front...

 

Thanks for showing your tips and tricks also!