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Mk1 Austin Countryman


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#136 minimikej

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Posted 21 June 2020 - 07:51 PM

Two steps forward and three steps back. I was gearing up to replace the windscreen scuttle, but started looking in detail at the corrosion around the edges. And then this happened.

 

50030717506_779a0d382f_b.jpg2020-06-21_08-36-16 by Mike Jackson, on Flickr


I think it was the right decision. Surface corrosion verging on the serious inside the A pillars.

 

50030181943_f4a4f15be8_b.jpg2020-06-21_08-37-06 by Mike Jackson, on Flickr


 

 

50030180403_70c2358f00_b.jpg2020-06-21_08-36-44 by Mike Jackson, on Flickr


 

 

50031008942_142c802d20_b.jpg2020-06-21_08-44-12 by Mike Jackson, on Flickr

 

 

50030207313_9252f24964_b.jpg2020-06-21_08-43-58 by Mike Jackson, on Flickr


 

 

Cleaned up with some rust treatment:

 

50030718336_87b7eb84cb_b.jpg2020-06-21_08-36-31 by Mike Jackson, on Flickr


 

The A post external flange and the roof skin are machine roller welded. No drilling out the spots here. Going to have to be extremely careful removing the old gutter to avoid damaging the roof skin.

 

Cheers

 


 



#137 Bdshim

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Posted 22 June 2020 - 04:47 PM

blimey got your work cut out, sure will work out just fine.



#138 Daz1968

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Posted 22 June 2020 - 06:11 PM

Same as I had to do, there is no paint in there so corrosion is common, the sponge on top corners rotted the top of my side panel out. 
one thing I will say is I had to remove the inner upper a post closers from the panel to get it in and then spot weld them afterwards, also the corner pieces of the cant rail are different on new panel so remove those and reuse ones on the car, and as you have good guttering I would salvage the corner pieces with drain cutout to weld in between new panel and existing guttering on side panel, mine was rotted out so I had to fabricate them, awkward but turned out ok, yours look like they can easily be reused.

2 of the wiper holes need welding up, the outer ones but what many don’t notice is the washer jet holes are also in the wrong place, I welded up ones in panel and drilled new in correct place.


Edited by Daz1968, 22 June 2020 - 06:13 PM.


#139 Grant 111

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Posted 22 June 2020 - 06:16 PM

Amazing work. Really impressive to watch this take shape.

#140 minimikej

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Posted 22 June 2020 - 07:32 PM

Same as I had to do, there is no paint in there so corrosion is common, the sponge on top corners rotted the top of my side panel out. 
one thing I will say is I had to remove the inner upper a post closers from the panel to get it in and then spot weld them afterwards, also the corner pieces of the cant rail are different on new panel so remove those and reuse ones on the car, and as you have good guttering I would salvage the corner pieces with drain cutout to weld in between new panel and existing guttering on side panel, mine was rotted out so I had to fabricate them, awkward but turned out ok, yours look like they can easily be reused.

2 of the wiper holes need welding up, the outer ones but what many don’t notice is the washer jet holes are also in the wrong place, I welded up ones in panel and drilled new in correct place.

Hey Daz1968, I think it was your write-up persuaded me to do it!!
So, when your windscreen panel surround arrived, were the inner A post panels you describe fully spot welded? On my panel, it is only spot welded to the frame, and not to the top corner curve at all. I was wondering if this is a revision to the panel so that the assembly can be fitted without surgically removing the closing panels first? What do you reckon? I'll try get a pic tomorrow to describe what I'm on about.

 

Thanks

Mike



#141 Daz1968

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Posted 22 June 2020 - 10:32 PM

I found with the roof on I couldn’t fit the panel in the space as the inner upper a post closers stopped me fitting it in the gap, if roof wasn’t on it would have fell in, I just drilled out the spot welds then plug welded them back in afterwards. The upper corner pieces I drilled out the spot welds then fitted the original ones after fitting the frame, these were a different shape so even though new ones would fit they didn’t look right. The inner closes have to fit in between the upper panel the heater vents and ashtray are in and it was here I couldn’t get them in there may be a way to do it but I gave up trying was easier to remove them.



#142 minimikej

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Posted 23 June 2020 - 11:02 AM

I found with the roof on I couldn’t fit the panel in the space as the inner upper a post closers stopped me fitting it in the gap, if roof wasn’t on it would have fell in, I just drilled out the spot welds then plug welded them back in afterwards. The upper corner pieces I drilled out the spot welds then fitted the original ones after fitting the frame, these were a different shape so even though new ones would fit they didn’t look right. The inner closes have to fit in between the upper panel the heater vents and ashtray are in and it was here I couldn’t get them in there may be a way to do it but I gave up trying was easier to remove them.

Yeah that makes sense, thanks



#143 minimikej

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Posted 14 August 2020 - 07:50 PM

I think the reason that the "horns" (inner roof rail corners) are a different profile is because on later cars the windscreen assembly tucks inside the side inner roof rails whereas on the earlier cars they sit on the outside maybe?

Anyway, I have rescued the original panels for refitting.

 

I've been really busy with domestic repairs, work and family recently, and with the bad weather and COVID keeping us all housebound I kind of lost all interest.

 

Sun's been out the last few days, and I've been out to see where I was up to.

 

Had to split the full windscreen panel into its constituent parts as described by @Daz1968.

Gradually fettling it into shape, but for me at least the porta-power is essential to do this job, otherwise the scuttle sits too low with respect to the dash rail.

50225789553_ea70ebfdbe_b.jpg2020-08-14_07-44-28 by Mike Jackson, on Flickr

 

50226655352_f89559d746_b.jpg2020-08-14_07-44-16 by Mike Jackson, on Flickr

 

Back on it in September all being well.

Cheers

 

 



#144 Standeman

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Posted 14 October 2020 - 10:43 PM

Once again, massive compliments on your great work - its a great picture story and is helping me massively with my restoration....looking forward to the newest update!!






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