1658 replies to this topic

[Deathrow]

Oh yes, they're quality!

My advice though, either cover them in oil/wd40 now or degrease them and get them etched and primed. The raw metal took like 24 hours to show surface rust where my finger prints were.

[Deathrow]

Finally managed to stop going backwards and start putting metal back in today!


Closing bracket was showing signs of rust so I thought I'd replace it while I was down here, I'd done the other side so I figured I might as well.


Found the outer lip was full of holes too so I chopped it out.


Cut out a repair.


Welded, dressed and red oxide applied.


Began making the card template for the floor/sill patch. I had marked it out on to steel as well but I don't have a picture of that.

Tomorrow, get that floor section welded in, repair the flange on the back of the companion bin and then the heelboard repair section will be going on. I'm hoping I can get that done and have time to start cutting out the other side ready to start repairing next week. If I really go for it now, I can have her ready for paint in a fortnight.

[mighty mini jack]

Getting there Adam,

[Deathrow]

Cheers Jack, can't wait for the welding to be done!

More work done today:


Repaired the spot weld flange on the bottom of the companion bin.


Made up the floor/inner sill patch, the magnets aren't holding it in place very well, it fits quite nicely.


Rubbed down and primed.


Made a patch for the remaining part of the inner sill. Is there supposed to be a spot weld flange on the back of this like this? How does the original inner sill attach to the heelboard, other than with the heelboard reinforcing bracket?


Rubbed down and primed.


Quick splsh of paint to protect them once welded in.

I'm going to go down tomorrow and see about getting those repairs welded in place ready for the heelboard panel to go on.

Thanks for looking .

[tedmcedd]

nice pannel fabricating there! what are you using to get your bends so neat?

EDIT: i cant spell!

Edited by tedmcedd, 04 September 2010 - 10:20 PM.

[Deathrow]

A hammer and a piece of wood Ed hehe.

I maintain that I think the end of my inner sill is wrong though, I don't think it should have a flange for spot welding. I think the end of the sill is supposed to be seam welded to the heelboard from inside the companion bin, alot of fun that will be to do!

[sonikk4]

I fairly sure that there was a flange there before i replaced the inners on Erm. Instead of seam welding try plug welding instead if you have got poor access. I would drill up through the heel board and plug weld that way. I'm lucky i have got the access as i will seam weld the inner sill to the heel board.

[panelbeaterpeter]

Looking spot on. It's such an awkward area to repair with all the spot welds and the thickness of metal, but you're doing a good job

[Deathrow]

Cheers guys. I'll leave the flange on there then and plug weld it as the access is rubbish, either way, it'll be plug welded on that side and the other side of the heelboard will be held with the right angle bracket that holds the bolts, can't see there being an issue of strength!

[Deathrow]

More done today, this side is almost done!


Repair sections tacked in place. I offered the heelboard repair up to check they were in the right place.


Seam welded up.


Welds dressed.


All welded in.


Subframe used to offer up heelboard repair. Needs to be shortened a little bit to fit in the right place.

I'll whip the heelboard section back out tomorrow, shorten it and drill the holes needed for plug welding.

Thanks for looking .

1000th reply!

[analogue_radio]

Brilliant Adam!

Do you think I'll have problems with strength as I don't have the rear bins anymore?

And are you plug welding the whole way around?

[Deathrow]

I couldn't tell you about the bins Luke, I've no idea.

I'll be plug wedling all round except on the left where the patch meets the heelboard, that'll be seam welded. Basically I'll be welding it back in as original.

[tedmcedd]

nice one! i have this to do on the mk2... when i eventually get round to it again xD

[jayare]

Looking good! On my Estate there was no flange on the back edge of the floor extension which fits up to the heelboard - just seam welded, but it may be slightly different on the saloon. In any case the repair you have made is at least as strong as the original,

JR

[Deathrow]

Looking good! On my Estate there was no flange on the back edge of the floor extension which fits up to the heelboard - just seam welded, but it may be slightly different on the saloon. In any case the repair you have made is at least as strong as the original,

JR

Cheers JR, I'll have to spot weld it as I just can't get access to the back of it to seam it to the heelboard.

I imagine the majority of the stress at that point will be transferred from the heelboard to the inner sill via the strengthening brackets joining them.

More tomorrow...well today, if I go to bed!