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Post by Penguin45 on Nov 26, 2013 1:02:29 GMT
Feeling much more positive now. Took some steel into college today and used the motorised guillotine to chop it to size, before one of my college chums helped with the metal folder (I haven't used one before) and Bingo! - inner sill repair panels.   Not a bad couple of hours work this evening and it feels good to be getting some new metal in. Chris. |
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Post by tommydp on Nov 26, 2013 23:24:05 GMT
Great work Chris! You are really working fast! I'm following with interest!
Tommy
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Post by Penguin45 on Nov 27, 2013 0:33:05 GMT
Tomorrow - the thrilling creation of the drop-down panel for the sill to weld to. This will be stepped (Joggled) and should be long enough to reinforce the void panel back by the displacer, which I have yet to make. It's just a flat panel.  This bit, in fact. New panel in, drop panel will reinforce it immensely. I'm taking a big sheet of metal into college tomorrow, so I'll make about 2.5 metres of 30mm strip. We've got a joggling machine, so it'll take about 15 minutes. Lovely. Chris. |
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Post by dave1800 on Nov 28, 2013 2:33:22 GMT
Arrived back last night after a few days away staying high in the mountains (hills in Tommy's speak) where it was a cool 18C, no WiFi access and patchy phone signals. Peace! I notice that repairing the sills you do not appear to have braced the car to avoid body distortion and difficulty getting the doors to fit afterwards? Is this not really necessary I wonder. I have seen photos of temporary braces welded across the door frames when the sills are being cut out. I guess it depends on how much you are removing at a time. Regards David Tomorrow - the thrilling creation of the drop-down panel for the sill to weld to. This will be stepped (Joggled) and should be long enough to reinforce the void panel back by the displacer, which I have yet to make. It's just a flat panel. Chris. |
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Post by Penguin45 on Nov 29, 2013 0:19:04 GMT
We'll find out later.......... Eugenie was fine and she was in worse condition. To be truthful, I have measured across the angle of the door apertures front and rear (Can't find piece of paper....) and the deflection is not measurable - 0.5mm if I'm being paranoid about it, but that could well be just a measuring error. Managed an hour and a half in the garage this evening.  Made these up at college yesterday. 30mm strips with a step/joggle rolled in on the Jenny. As you can see, I have started adding the holes on the pillar drill - about 70 by the time I'd finished. The strips will be plug welded along the bottom of the repair panel to give the bottom edge of the sill a mounting point. The piece of angle is going into the sill membrane.  Front end dealt with - I have had to cut out a vertical section entirely and replace it; then put the some of the angle section in to reinforce the bottom edge. Little bit of progress. Chris. |
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Post by Penguin45 on Nov 29, 2013 22:05:04 GMT
Drop panel for the sill bottom to weld onto and the flat panel back by the displacer now in place.  This needs seaming - it's held by a series of tacks at the moment. Halogen lamp bulb has failed, so not enough light right now.  Drop panel - 46 plug welds and I didn't blow through once. I'm getting better at this welding lark. Next target - repair rear jacking point properly and get the back end of the inner membrane repaired. Chris. |
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Post by tommydp on Nov 29, 2013 22:15:40 GMT
Very impressive, Chris! I'm so impressed, not only by your skills but how fast you're working!
Wish I could weld myself. One day... :-) My Scania lorry could really do with some welding to the cabin..
Tommy
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Post by dave1800 on Nov 30, 2013 5:09:48 GMT
This is a really excellent set of photos Chris and very impressive. David Drop panel for the sill bottom to weld onto and the flat panel back by the displacer now in place. Chris. |
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Post by Penguin45 on Dec 1, 2013 20:32:05 GMT
Membrane is all but finished and the sill fits nicely when offered up.     Lots of chopping out and welding in. Not too pretty but, my goodness, it's solid. Braced the jacking points back to the inner sill - probably stronger than the original ever was.  Rear panel now fully attached.  Little bit trimmed away at the rear allowed the sill to sit on nicely.  Today's act of bravery - bottom of wing cut away for access to front end of sill. I suppose it will be easier to repair on the bench anyway.   Angle piece to door pillar is crimped into the back of the wing edge. Going to open that, de-rust, repair wing section and make up a new piece of bracketry. I had hoped to get the sill at least tacked on, but a problem with the jacking point tubes has arisen - they are too short. They should just protrude through the sill and be welded - they are about 5mm short. If I don't replace or extend the tubes, water will get in and some years down the line someone will be doing this job again. Mr Bodger from the previous sill repair again, no doubt. Having come to a halt, I seam sealer-ed all the welding to date, and painted various bits with red Hammerite. Well, it's a red car. That said, I didn't expect the full vibrancy of pillar box red....... Chris. |
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Post by Penguin45 on Dec 3, 2013 21:55:21 GMT
Tube - give me 24mm ID tube.......... It'll be here Thursday of Friday. In the meantime, I've started on the N/S rear arch section.  Cutting away the rotten lip revealed an intact inner arch. Plastered it all with rust converter anyway. It was at this point that Theo and I found Eugenie's inner arch was made of newspaper. We went to the pub and drank to mild excess.  Repair section trimmed roughly to size and offered up. I think it's going to look fine. Chris. |
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Post by bullyboy on Dec 4, 2013 8:00:11 GMT
Hi Chris
Were did you get the repair section for the arch? can you get the whole arch? Working on mine last night tried to drop the rear bumper off,bolts turn but so did some of the body work. I thought that you project was a big job but what i am still finding is that i am not far behind you with rust, what scary is i have been driving this car and i think if i would of hit somebody there would be nothing left of the car or me and probably killed anybody watching with rust shrapnel. Keep going, you are inspiring me no end, i nearly gave up last night with what i found.
Paul
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Post by andrewa on Dec 4, 2013 8:25:35 GMT
Couldn't agree more - my car v.similar under a reasonably pretty exterior. Previous bod did circa 100 miles a year and obviously had a "friendly" mot chap. Mainly as a result of following your thread I've enrolled on welding course which starts next year - shame I didn't do the course before I bought the car.
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Post by dave1800 on Dec 4, 2013 8:50:49 GMT
Hi Paul I think the safety issue you raise is very important. The 1800 shell despite being very strong when produced relies almost entirely on box sections created from relatively thin steel so it is essential to keep it sound. As Chris has previously pointed out it is straight forward to repair (at least for him  ) but time consuming so welding skills or a deep pocket are needed. regards David Hi Chris Were did you get the repair section for the arch? can you get the whole arch? Working on mine last night tried to drop the rear bumper off,bolts turn but so did some of the body work. I thought that you project was a big job but what i am still finding is that i am not far behind you with rust, what scary is i have been driving this car and i think if i would of hit somebody there would be nothing left of the car or me and probably killed anybody watching with rust shrapnel. Keep going, you are inspiring me no end, i nearly gave up last night with what i found. Paul |
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Post by bullyboy on Dec 4, 2013 18:56:30 GMT
Hi David
Luckily for me i do have the skills and the equipment, could do with more space, its time that is the issue for me, but my goal of April 2014 still stands at the moment. I just need to get on with it like Chris, keeps me out of trouble
Paul
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Post by Penguin45 on Dec 4, 2013 19:26:30 GMT
Agree, Paul - the Mrs knows where I am.  The repair section for the arches have come from the Maxi Owners Club. They are too short and have a flat lip which will have to be built up, but as front and rear sections they'll be absolutely fine. As for skills, they have been just acquired over the years, usually driven by financial necessity. Welding, well, there's nothing for it but to give it a go. Thanks to the college course, I have become much better at it and have pretty much stopped blowing holes in things. Safety - I couldn't knowingly drive around in something I know to be unsafe, so we should all have a small pat on the back for recognising the problems in the first place and setting out to resolve them. Chris. |
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) but time consuming so welding skills or a deep pocket are needed.
The repair section for the arches have come from the Maxi Owners Club. They are too short and have a flat lip which will have to be built up, but as front and rear sections they'll be absolutely fine.