948 replies to this topic

[panky]

I would use tech screws or self tappers to pull the two together and weld up the holes once you've finished the rest.

[stuart bowes]

good work mate, that looks pretty solid to me :) 

 

just a little thin smear of filler later to make it invisible and job well done

Edited by stuart bowes, 28 December 2022 - 05:44 PM.

[colinf1]

If you have a trolley/bottle jack, you could push the floor up to get a tight fit to the crossmember.

Looking like you're making good progress even with these annoying little set backs!

[Viktor]

I got started with welding the cross member.

 

I applied 2 coats of zinc primer to the area under the cross member. It cannot be seen, but it's there...

 

 

Then I prep the cross member, cutting holes along the flanges in contact with the floor and tunnel.

 

 

 

Then I used my hydraulic trolley jack to push the floor against the cross member.

 

 

The 2 panels closer to the tunnel are completely flush with the cross member, however the third needed a screw to get it in position.

 

 

I cleaned up the paint in the plug holes with a flat screwdriver, to ensure good penetration and better connection between both panels.

 

 

Then I started welding...

 

 

Looks like I got good penetration as per the marks underneath the car.

 

 

That was all for today, as we spent most of the day out.

 

I'm planning to continue welding the cross member tomorrow.

 

Victor.

[stuart bowes]

I like the little game of jenga you've got going on there with the stack of wood lol

 

looking good don't forget also the Vizard has some comments on extra welding around the cross brace, let me know if you don't have access to that I'll see if I can find the page again and post a pic

[gaspen]

Why don't you use self-tapping screws ?

 

 s-l500.jpg   36.8K   0 downloads

[Viktor]

I like the little game of jenga you've got going on there with the stack of wood lol

 

looking good don't forget also the Vizard has some comments on extra welding around the cross brace, let me know if you don't have access to that I'll see if I can find the page again and post a pic

Hi Stuart, that would be great if you could, thanks.

[Viktor]

Why don't you use self-tapping screws ?

 

s-l500.jpg

Good question! I have to order some!

 

Cheers.

 

Victor.

[Viktor]

Not much done today, as I run out of wire for the Mig welder

 

I managed to complete half of the cross member. Some welding here, once I managed to put both panels together.

 

 

A couple of plugs in the central tunnel.

 

 

View from underneath...

 

 

Grinding down the welds

 

 

 

And some primer to finish it off on this side.

 

 

 

The welding wire should arrive tomorrow before lunch. I will carry on then...

 

Victor.

Edited by Viktor, 30 December 2022 - 04:12 PM.

[stuart bowes]

As it turns out I've promised something I can't actually provide lol

 

I'm really annoyed because I KNOW it exists, I distinctly remember seeing a diagram explaining where to do extra welds, but it's not in the Vizard that I can see (and now thinking about it the book I have is all about the engine not bodywork).  I checked the Bill Sollis book as well, it's not in there

 

dammit.. must have been something I saw on a forum or something.

 

anyway I think the general gist of it was seam welding mostly around the 4 corners of tunnel / crossmember section (i.e. the middle)

 

for myself personally I was probably just going to stich weld it all along both sides and the ends,  that might be overkill but it can't hurt in my opinion anyway whatever that's worth (maybe very little)

[Viktor]

Happy new year everyone! Hope 2023 will bring progress to your projects ;)

 

Thanks Stuart, I have added seam welding in all corners of the cross member, just to make it a bit stronger.

 

I have completed the welding of the cross member on the driver's side. Same process as per the passenger's side.

 

Very important to have good lighting when welding...

 

 

All done now...

 

 

 

And against the inner sill

 

 

And from underneath.

 

 

I didn't have time to do any grinding, which will be happening tomorrow.

 

Victor.

[colinf1]

Are you going to put a weld along the front of handbrake bracket to crossmember? Mine was broken here, and when I welded it, it turned out to be brazed. It's welded now though!

[Viktor]

Hi Colin, I haven't but it seems a sensible thing to do, to give it more strength! :)

 

Today I finished grinding the cross member.

 

 

 

And applied some primer to protect it

 

 

 

Next I moved to the rear jacking bracket. Setting out and prep...

 

 

 

Welded in position.

 

 

 

Grinded

 

 

And painted...

 

 

The floor is now completed, so I guess now I can remove the bracing? Please let me know, just in case I should leave it there for a little bit longer.

 

Next will be either the quarter panels, or the rear valance and closing panels. I also have to do the battery box.

 

Plenty to do! :)

 

Victor.

[Viktor]

Last day of holidays, coming back to work tomorrow...

 

I went around the car and fixed some bits and pieces.

 

I also finished one of the companion bins, which needed some welding against the inner sill.

 

 

 

I also removed the bracing from the car, to have a bit more of room.

 

 

I still need to clean up the bits on the companion bins, but that will happen next weekend.

 

Victor.

[Viktor]

Quarter panel time!

 

Just following the same steps as Ben in his current project. Some photos of the process...

 

Cleaning up the companion bin and wheel arch lip

 

 

 

I finished welding the seat belt bracket, as for some reason wasn't taking the spot welder everywhere, just in some areas, so I plug welded the rest.

 

 

 

Then all primed ready to receive the quarter panel.

 

 

 

Quarter panel clamped in position, so I can mark-up where to cut the B and C posts.

 

 

 

Then I prepared the panel, removing the black paint and applying zinc primer. I also applied zinc primer to the wheel arch lip.

 

 

 

 

Cutting the B-post revealed some rust underneath...

 

 

Then I started spot welding the wheel arch and the window edge. My spot welder cannot reach along the outer sill, so I would need to get another set of arms...

 

 

 

 

Tomorrow I will plug weld the edge along the B-post and the joints with the old panel above the window edge.

 

 

Victor.