155 replies to this topic

[minimikej]

Repairs to the toeboard/bulkhead flange -

 

2018-11-11_08-09-36 by Mike Jackson, on Flickr

 

The area around the accelerator pedal captive screws and the lower pedal box mounting captive nut was thinner that I thought and so I ended up cutting more out and more welding.

2018-11-25_12-28-35 by Mike Jackson, on Flickr

 

2018-11-25_12-28-51 by Mike Jackson, on Flickr

 

Tiny bit more grinding to to if I'm feeling fussy, then need to re-drill and replace the captive screws/nuts I chopped out.

[minimissions]

Nice work there mate, any word on your floor arriving?

[minimikej]

Nice work there mate, any word on your floor arriving?

 

Cheers!

And no  

Placed the order Oct 4th. Phoned Doreen Nov 5th, was told it'd be a couple of weeks.

[minimissions]

 

Nice work there mate, any word on your floor arriving?

 

Cheers!

And no

Placed the order Oct 4th. Phoned Doreen Nov 5th, was told it'd be a couple of weeks.

 

Thats crazy mike, well lets hope its here very soon, talking of taking their time

[minimikej]

I was allowed out into the garage this afternoon so I got stuck in on the boot floor repair where it joins the heelboard.

 

I had to take out the rear seat flanges on the rear bins which I was hoping not to have to do, but the bins were more rotten than I had thought so I'll have to replace or repair them anyway.

 

I cut along the front edge of the boot floor, used the joggler to create a step, and plug welded the repair through the original boot floor. I may decide to run a seam weld from side to side from underneath but can do that later.

 

2019-01-03_06-07-11 by Mike Jackson, on Flickr

 

2019-01-03_06-06-59 by Mike Jackson, on Flickr

 

It wasn't easy getting the rear bench supports off the bin panel because you can't get a drill and spot weld cutter in after half way because of the triangular shape of the support.

 

2019-01-03_06-06-37 by Mike Jackson, on Flickr

 

 

And just then I got a call from Doreen at M-Machine telling me my panel order is ready for delivery which was great news. That's a full quarter of a year to build the floor panel! If I had known it would have taken so long I would have gone for the new Magnum mk1 Traveller full floor pressing which looks really nice and built up a full floor myself. But I'm happy that things are moving again.

 

I didn't plug all the way to the sides of the car because I've got repair panels to let into the boot floor corners, or at least I will have when the order arrives.

 

It's also not easy getting an angle grinder between the spare wheel well and the front edge of the boot floor so I couldn't clean the plug welds up as much as I'd have liked. Might have to invest in one of those narrow belt sanders.

 

When the order arrives I'll fit the new toe-board after having refitted the front subframe, and then get the new floor dropped into place. I'll have to secure it with clamps and self tappers for now because everything along each side and doorstep will need to be chopped out and replaced.

Edited by minimikej, 03 January 2019 - 06:35 PM.

[minimissions]

Nice progress Mike, looking forward to seeing that floor come into place.

[minimikej]

And then all the panels arrived.

 

Got them all etch primed in the cold

 

(pan is sat on the roofrack fitted to the red saloon by the way!)

2019-01-05_07-15-01 by Mike Jackson, on Flickr

 

 

Floor pan looks okay but not as tidy as the one I had for the mk1 saloon:

 

2019-01-05_07-14-46 by Mike Jackson, on Flickr

 

Quite a kink to iron out on the near side:

 

2019-01-05_07-15-15 by Mike Jackson, on Flickr

 

Then started to line up the new toe board. The dimples where the brake/fuel lines go are considerably deeper on the original, compared to the Heritage panel. Old tooling maybe? I decided to slot the original bulkhead and flatten the salient, it'll not be seen:

 

Bad pic sorry, flash didn't fire:

 

2019-01-05_07-25-29 by Mike Jackson, on Flickr

 

Clamped, bolted and Clico-ed in place:
2019-01-05_07-15-28 by Mike Jackson, on Flickr

 

Subframe back on to check alignment. Happy to say it fits really well.

2019-01-05_07-15-43 by Mike Jackson, on Flickr

 

2019-01-05_07-16-00 by Mike Jackson, on Flickr

 

2019-01-05_07-16-12 by Mike Jackson, on Flickr

 

Next job will be to remove the subframe again and get it tacked into position, then refit subframe and work out a way of hoisting the floor pan into place in a controlled way. On the mk1 saloon I jacked the pan into place from below but it was a real pain removing and refitting it after every tickle with the grinder.

Edited by minimikej, 05 January 2019 - 07:36 PM.

[g111mds]

Lovely work on this :)

[minimikej]

Forgot to ask, does anybody know what the jacking point setup supposed to be like on a late 61 Traveller? There's no jacking reinforcement panel either side of the cross-member on this assembly, but neither is there the square hole for the jack, just a round hole further back?

[KTS]

...there's something very wrong with that floor assembly they've supplied - almost as if the inner sills/floor returns have buckled under compression when the heel board was attached

[KTS]

Forgot to ask, does anybody know what the jacking point setup supposed to be like on a late 61 Traveller? There's no jacking reinforcement panel either side of the cross-member on this assembly, but neither is there the square hole for the jack, just a round hole further back?

Pickup floor pans are like that - the hole is for the load bed drain

[minimikej]

 

Forgot to ask, does anybody know what the jacking point setup supposed to be like on a late 61 Traveller? There's no jacking reinforcement panel either side of the cross-member on this assembly, but neither is there the square hole for the jack, just a round hole further back?

Pickup floor pans are like that - the hole is for the load bed drain

 

Do they not have a jacking point on the sills then? (Sorry, my first Traveller, don't know different)

Or, are these the wrong sills for a late 61 Traveller?

Edited by minimikej, 05 January 2019 - 08:46 PM.

[minimikej]

...there's something very wrong with that floor assembly they've supplied - almost as if the inner sills/floor returns have buckled under compression when the heel board was attached

 

Hmm. I would tend to agree with you. It's fixable but I would rather not have to. It might all clamp up once the companion box reinforcement goes in. But truth is I'm pretty disappointed with M-Machine this time. Looks like a rushed job, but took 3 months. The stitch welds they put between the heelboard and the floor are really noticeable and there's a gap between heelboard and floor pan. I'll get more pics tomorrow.

[mini_in_progress]

...there's something very wrong with that floor assembly they've supplied - almost as if the inner sills/floor returns have buckled under compression when the heel board was attached

Yup, almost too perfect to ripple bith sides at a simlar place, did it show signs of damage before prime?

Looks a great project tho bud, keeping a close eye on this for inspiration

[KTS]

Forgot to ask, does anybody know what the jacking point setup supposed to be like on a late 61 Traveller? There's no jacking reinforcement panel either side of the cross-member on this assembly, but neither is there the square hole for the jack, just a round hole further back?

Pickup floor pans are like that - the hole is for the load bed drain

Do they not have a jacking point on the sills then? (Sorry, my first Traveller, don't know different)

Or, are these the wrong sills for a late 61 Traveller?

Just checked the Heritage panel listing and they list the same outer sill for van, pickup and traveller, so looks like travellers didn't have the jacking point off the end of the cross member.