625 replies to this topic

[vince1969]

OS wing off! Steering rack bracket off! Other little rust traps OFF! (santa brought me a spot weld drill bit for christmas)


mmmm. crusty. I plan to clean bits like this up, kurust and paint, then stick them back on.


This is my first piece of sheet metal fabrication. I think it went quite well for a total amateur!


It was becoming clear that the scuttle had to come off to fit the inner wing. I'd been umming and arring about just getting repair panels for the corners, but in the end I splurged the extra cash on a full heritage scuttle so that I wouldn't have to risk any welds in the middle not being perfect. At this stage, I've got absolutely not idea how I'm going to treat the rust in the windscreen pillar! eek.


This is where I left it today. Hopefully this will be the last major chunk to come off before I can start rebuilding the near side.

definately a good move replacing the whole scuttle ,i did the same on my pickup the heritage panel fitted a treat..

[rich2]

Continuing with the metal work on the inner wing area, I chopped off the rotten section of the dash shelf, and made a template for the repair.


After much trimming and bending and swearing, I had fabricated the required piece.


Welded in and dressed down. Its difficult holding a grinder in that tight space without severing one's fingers.


Then on to the lower firewall disaster zone...


Chop the rot!


New piece made up to size. I measured it as accurately as I could against the new inner wing. Since the new inner wing doesn't fit very perfectly (yet), I'm pretty sure the curved edge will need whacking with a hammer at a later date.


Welded in and ground down. I also kurusted the surrounding area in the meantime, which is why the metal looks black.


A dusting of etch primer over everything.


Here is a little before and after of this area to show the dramatic improvements! The first pic is from a couple of weeks ago.


So progress is definitely happening, but it is sloooooooow. I'm doing a lot of this stuff for the first time and its taking me a while to work it all out. I've also fabricated new brackets for the bonnet hinge on this side as the old ones were NBG. The next thing to worry about is what the hell I am going to do with the door post. It looks like its going to be a nightmare. I don't even want to think about it at the moment!

After all that mucking around with bits of steel, I felt like doing something mechanical; so I stripped the front subframe. Satisfying! I didn't even have to destroy anything in the process!


BITS:


That is all! If I'm doing anything wrong/stupid, please tell me!

[Boycie]

Nice work, you're doing great!

[Juju]

Cripes, you have patience!

I like this thread. Clean, highly skilled & innovative.

[willyg]

props to you for the work so far man! love it looks well tidy

[Goacher65]

Looks good. I've got this one tracked. How are you going about lining up your inner wings? Both are to be replaced on mine so just wondered if you had any ideas on how you are planning to do it. Also, how is the clarke 135te? Is it manageable for someone completely new to welding? I am in the same boat as you and thats the one i had my eye on getting myself. What gas mix are you using?

http://www.theminifo...howtopic=178485

Keep an eye on this, and when it makes it to the garage and I make the first start on it you may see a simlar sort of thing happening to mine

Howard

[rich2]

Thanks guys!

Howard: I plan to line the new OS inner wing up with the old one which I have left on for reference. I'm going to buy a new front panel complete, clamp it all up, offer up the front subframe, make sure its all level and cleco the inner wing in place. Then when the new inner wing is welded in, I'll start of the other side. At least that is my plan at the moment!

The clarke 135te is pretty good I think, but its the only welder I have used so I don't have anything to compare it to. From a complete beginner a few months ago, I'm now able to make solid welds with it, and it hasn't let me down yet. I'm using BOC argoshield light which I believe is 5% CO2, 2% O2, and 93% Argon.

Good luck with your project! You've got a nice collection of panels there. If I'd seen this for sale, I might have gone for it myself!

[minidream94]

OMG mate thats some amazing work there i've got to repair my inner and outer wings on my estate, so will be watching your build every update that is made

How hard is it to remove the inner wings as a whole? is there many spot welds holding it on?

Cheers

Nick

[Mini Mad Drakeley]

wow, good work lol, im learning to weld and then il be the same as you but i have less patience lmao so something is gona go wrong and im glad i dont have as much as you, i just need to replace the front end excluding inner wings, two front floor pans the rear valance and lots of patches lol, but it looks great and keep up the good work

[rich2]

How hard is it to remove the inner wings as a whole? is there many spot welds holding it on?

On my car there was a large patch repair in the footwell which was seam welded to the door post, so there was nothing to do but cut with the grinder. The front end is quite easy to drill out the spot welds, but the lower bit which joins to the firewall is double spot welded (on two flanges). Not really easy to get out in one piece. I think it took me a good few hours.

[blacktulip]

mate, i take my hat off to you. your doing a great job. reading this i know what i have got myself into with my clubman estate

[sonikk4]

That's a nice little repair piece for the inner wing stiffener. Its better now to get all of the niggley rusty bits rather than the evil rust to re appear when the car has been painted.

I'm still finding little bits here and there (found a bit i had over looked a year ago but sorted that out) but Erm is nearly ready for his shiny new coat.

[Glenn S]

Rich I have 2 Brand new brake drums that I did not use on mine. Free if you want them,@ Kimberley Nottingham.Let me know

[rich2]

Rich I have 2 Brand new brake drums that I did not use on mine. Free if you want them,@ Kimberley Nottingham.Let me know

Glenn: that would be most awesome! PM'd

[Artful Dodger]

I really like everything about this resto!fabrication is brilliant! i only have a hammer and a vice to bend steel:/ really nice!!


what are your plans for it when its time to style???