395 replies to this topic

[stuart bowes]

Cut out reinforcement plates (1.5mm takes a bit more effort doesn't it!)

 

 

Obviously there was a lot of time spent fettling, and wire brushing up the underside of the car where it fits, etc, so only got one tacked in today (no rush anyway I suppose)

 

 

welding will be tidier when I settle into doing it properly, obviously

 

I do realise these are huge compared to the originals but that's fine by me, the marginal extra weight is more than a fair compromise to make sure that the repair is strong.  considering the importance of having strength in this area and me not exactly being an expert at welding 

 

The obligatory check with the yardstick (although it probably wouldn't be able to move now anyway)

 

 

and while there I sorted out inside the wheel arch (compare to post #91)

 

 

Just a scrape of filler needed to pretty it up, and little trim off the edge when the rear quarter is fitted, but it's solid and the fabricating is done

Edited by stuart bowes, 12 October 2022 - 07:26 PM.

[stuart bowes]

Cleaned up underside, fettled fitted and tacked in drivers side plates, again vastly oversized but more than happy with that

 

 

Then did some exploratory wire brushing to find out what other issues the boot floor may be hiding, turns out, basically not much at all

 

 

Age-old repair highlighted with green line, possible rear ender at some point? looks reasonably well done and pretty much the same age as the rest of the car judging by the surface rust

 

Rust hole highlighted with red circle

 

Battery tray a bit tired, looks like some numpty has jacked the car up on the bottom right corner, was dented in and rusted through

 

 

So I cut that bit out and tacked in a new section

 

 

 

The other smaller issue actually cleaned up and looks like it might just need a bit of kurusting, I'll leave that for now and have another look later when I get all the old muck and paint out 

 

 

Finished off the day by sorting out the rust hole in the wheel well.  actually did all the welding on this one seeing as it was small

 

 

 

I'll do a better final dressing on that later when the rest of the boot is being done

 

So basically now I've just got a whole bunch of welding to do then I can put the sides on

Edited by stuart bowes, 13 October 2022 - 05:24 PM.

[stuart bowes]

looking at that battery box patch again I've decided I'm not happy with that so I'm just going to order a replacement box, it's not like they're earth shatteringly expensive is it.  Then it's just a nice easy plug weld job and saves on gas and grinding discs anyway

 

Also, with it out of the way I can clean up the underside more easily.. win/win

Edited by stuart bowes, 13 October 2022 - 05:53 PM.

[Viktor]

Hi Stuart,

 

I ordered my battery box from Magnum, and unfortunately it doesn't fit perfectly on my heritage boot floor. It would need quite a lot of adjusting. I have parked that in my project for now, but once I'm back in that area I might order the heritage one instead.

 

You might want to consider spending a bit more and get a heritage one. It would probably save you time...

 

Victor.

[stuart bowes]

Ah that's interesting, I've already ordered the cheaper option from minispares.. I don't know what brand that is but it did say 'very common ordered and no complaints about fit' or words to that effect

I guess I'll just have to wait and see but still I reckon fettling that is gonna be easier than bodging my old one

[Gilles1000]

If I were you I would add welds on the reinforcing plates, by drilling holes in them and pluging them to the boot floor.

You will have more strength with that, although as they are already welded I do not know if it's still possible.

 

Good progress

[sonscar]

Just drill holes part through from the top and plug away,nice and easy,Steve..

[stuart bowes]

I'm going to do more welding on those, that's just to hold them in for now, I was probably gonna sort of stitch weld all round unless I get carried away and fully seam weld but I don't feel like that's necessary

But also as I still have the welding from above to do (See post #104) I reckon that will penetrate into the larger piece quite a lot

Edited by stuart bowes, 14 October 2022 - 04:18 PM.

[Viktor]

That is how I did mine, but I got the drills before putting the plates in.

 

View from the top:

 

[stuart bowes]

That looks pretty solid, to be honest I'm getting penetration marks very similar to that just as it is with the tacks I've done so far so I know its pretty solid

[stuart bowes]

Near side rear quarter back in stock and ordered

New (to me) petrol tank found on ebay £30 plus a 2hr round trip, worth it though as it looks in pretty good condition rust free and allegedly clean on the inside as well which can only be better than the one I pulled out

Edited by stuart bowes, 14 October 2022 - 02:57 PM.

[stuart bowes]

Got the tank, very clean total bargain for £30, fitted with a new sender unit as well which is a bonus

 

also removed the old battery box while waiting for the new one

 

 

 

Edges tidied up straight after that, and I've left the old surround flange in for now because it's rust free and adds a bit of strength to the edge of the hole, will do more on that later

Edited by stuart bowes, 16 October 2022 - 09:27 AM.

[Sunnymini]

watching closely as i have all this to come!

[stuart bowes]

Righto so the battery tray wasn't quite what you'd call a perfect fit..

 

 

Marked up where it needed to be

 

 

cut little slits to assist with the bends

 

 

Flatten out the old useless lip 

 

 

This is where it's a bit tricky because already being a box makes it difficult to get the bends in, can't just use the sheet bender like I would usually prefer, so it's just on the vice to gradually work along the bend and using a hammer to get it tight

 

 

 

Then marking up what I want to keep (use the meat of the existing tabs to create new ones)

 

 

Cut off excess, tidy up a bit with the power file and voila:

 

 

same with the back side

 

 

 

and trial fit

 

 

Ooooo so close

 

 

might give the floor a little upwards whack to see if I can close that up, otherwise it's a slight adjustment required, all other edges spot on. 

 

Finish that off another day

Edited by stuart bowes, 17 October 2022 - 06:54 PM.

[stuart bowes]

and just won 2 new door windows for £16 the pair, have to drive to Kent but never mind.  bargain

 

makes up for when I ruined my drivers door glass by welding on the door without covering it up.. rookie error