51 replies to this topic

[82hle]

Thanks for the input again, fellas - I appreciate it.

Spent a couple of evenings filling and sanding all the little ubbly-grubblies on the front end. Started by dribbling paint (finnegans no1) down the various joints and brushing it into the seams. Then a few skims of filler on anything that didn't look or feel quite right.

Front wing needed a bit of filling where I managed to dent it while trying to wrestle it into a better fit with the scuttle.


The fit to the scuttle, while not great, does not now look too bad with some filler in the gap. This was by far the worse side.


Front of this wing just had a little wipe along the join plus a bit of smoothing of some rough file marks on the wing. there was also a little dent and a bit of concavity on the front panel that needed improving.


I struggled to get this wing to align with the front panel and it needed a bit of filler to get a smooth surface. This side also needed filling at the wing a-panel joint which I fully seam welded on the inside - definately not remommended. I also managed to put a little dent in the top of the wing when I had it upside down on a bench while welding the wings, front panel and a-panels together


That's how it sits right now on this sunny Saturday morning. I want to get some primer on and a coat of paint to seal it.
Then I still have a few welding jobs to tackle and other bits to get ready for paint.

I don't know if I'll just do a bit at a time of save them up and do them all in one go.

But, for now, I am a little happier with how it looks now I have a bit of filler making the fit of the panels a bit better.

Mart.

Edited by 82hle, 24 April 2010 - 08:19 AM.

[Shifty]

I'm gonna have to make you unhappy again..........sorry dude!!

If you use filler in the gaps between the panel joints the filler WILL(no question and totally guranteed) crack and then ruin your paint job. No matter how well you've weld the panels together the front end will flex and as the filler can't flex it cracks instead. Use flexible seamsealer in the gaps, that what the factory used and the best choice by far.

The fillers ok on the dents, just not the gaps/seams

Sorry

[82hle]

I'm gonna have to make you unhappy again..........sorry dude!!

If you use filler in the gaps between the panel joints the filler WILL(no question and totally guranteed) crack and then ruin your paint job. No matter how well you've weld the panels together the front end will flex and as the filler can't flex it cracks instead. Use flexible seamsealer in the gaps, that what the factory used and the best choice by far.

The fillers ok on the dents, just not the gaps/seams

Sorry

Thanks Shifty, point noted, filler dug out and sealer applied.

[82hle]

Right.
A bit more progress to report.

Didn't feel too great over the weekend, but dug out the filler and redid it with seam sealer. Gave the areas of the front end a couple of coats of spray putty. Must admit the can was pretty old and it came out a bit runny. Looks not too bad after drying, though, and will sand back ok I think. I just wanted to cover the filler and bare metal with something.

Felt a bit more like doing something tonight, so launched in and cut out the two areas of the driver's doorstep that needed attention, made up some patches and welded them in. again, not perfect, but I was more intenty on making an effective repair than a full 100% restoration. My aim is to get this car on the road and drive it, not show it.

I also welded a little patch in the passenger wheel well where the sill attaches at the front, but forgot to take a picture. Will add one next time.

Here are some snaps.

Repairs to the driver's doorstep:


and:


Here's how they looked:


and:


And the front with a little bit o' paint on:


and with the lights placed in, just to see the contrast and envisage the finished look:

Oh yeah, my little welding cart (subject of a thread somewhere) is ACE!

and the wing to scuttle fit:


The a panels recieved a little tack at the top and a couple more lower down, just to stop any movement:


Feeling pretty pleased right now, as there are no more welding jobs to be done around the front end.
The sills are done, the floor has been repaired, the front end is on.

Only job now remaining that will require a welder is some minor repairs at the rear and fitting the valance.
There's only one way to get these jobs done and that's to just keep pecking away at them bit by bit.

Mart.

EDIT:
Here's the picture of the little patch:


And a better picture of the welding cart of goodness:


Mart.

Edited by 82hle, 26 April 2010 - 09:05 PM.

[Shifty]

Thats looking good now, nice job!!

Won't be long till its back on the road eh?

[mk3 Cooper S]

Looking good now.

i would put soe sea sealer in the A panel to iner hinge panel joint to stop it filling up with muck and rotting.

I have racked my brain about your car.Did it used to live Nr Light Hall school?

[82hle]

Looking good now.

i would put soe sea sealer in the A panel to iner hinge panel joint to stop it filling up with muck and rotting.

I have racked my brain about your car.Did it used to live Nr Light Hall school?

Yes, I will seam seal the joint, I already did the other side, but left this side as it still needed the patch welded in.

Don't know about light hall school but the car was in Cranmore Boulevard, just down from Highlands Road.

Thanks for the input again.

Mart.

[82hle]

Progress report.

Been a bit unwell, just a bit of a cold but had little energy.

Felt better this afternoon, though, so launched in and did a bit.

First, welded in some little patches to repair some bits where I went through with the grinder when welding the sills. Had to do the one bit, as it was right by the seat belt anchorage.


Just mopping up the dregs now on the welding. (other than the valance, of course, that still needs doing).

Then after rubbing down the spray putty I awoke this old beast from a long slumber.



Dug out my old spray gear and laid on a coat of primer. Was really playing catchup on the learning as I havn't sprayed in many years - at least 10 - maybe more. Gave it a little drying time , a quick gentle rub over and filled the gun with yellow. Had to radically readjust the gun, but got a reasonable delivery of paint going. I'm using cellulose.

Got two or three coats down and decided that will do for now.

Here are some pictures.

General view after closing the bonnet and putting the lights in place for contrast.

Of course I didn't spray it with the bonnet closed - I shut it to check colour match - not bad I think. I should have at least tried to mask off the engine - it's covered with overspray now. - lesson number one on the learning curve.

I made sure there was plenty of paint on the returned edge of the a-pillars.


Finish not too bad straight out of the gun:


I had a couple of nasty splatters - probably from not cleaning the gun properly - I said I'm on a learning curve here - so will have to give it a final top coat, but I'm more than happy with how it looks for now.

I can now carry on with refitting the doors, and prepare any other bits of paint that need touching in - and then do a final paint session all in one go.

I'm feeling very pleased with my efforts this afternoon - especially as it decided to chuck it down 1/2 hour after I finished.

Oh yeah - before anybody says anything - I am an incredibly untidy worker - I just saw how much crap is lying around not put away properly!

Mart.

Edited by 82hle, 30 April 2010 - 04:17 PM.

[Shifty]

Nice work there, my garage is just as untidy!!

I'm gonna have a 10p bet with you here!!!

I bet that you end up repainting the rear of the car because the shiny new front end makes the rest of the car look scruffy!!

(I know because I've done it myself!!)

[82hle]

Yeah, Shifty - That's one bet you'll probably win! LOL.

Ok, just came in from the garage after what I hope may be one of the last welding jobs - the rear valance.
I tend to seriously overthink the jobs and in the end just have to launch in and give it my best shot.

I found a little bit of rust in the right rear corner and chopped a little section out:


I cut a little patch and welded it in.


The valance closing panel on the right was ok, but the one on the left was no good. I made up a replacement piece, and welded it in. For some reason, I really struggled with the welding and after failing with plug welds, removed it anmd seam welded it.


I then decided to plug weld the rear of the valance, but awoke this old beast from a long slumber:


..and spot welded the lower edge of the valance to the filler panels.


And at long last the valance is finally secured in place.


I am really glad I bought the heritage panel, it fits great.

Like I say, hopefully I've now finished all the welding jobs. So I can now have a good tidy up and start trying to protect all the panels and the whole underside of the body against the dreaded rust. Then paint what needs painting, reassemble and get 'er running.

Have found a big pool of oil underneath the engine so it looks like the output shaft oil seals and the selector shaft seals need doing.

Plenty done, plenty still to do, and plenty still to think about.

Thanks for all the comments and guidance given so far, all comments welcome.

Mart.

Edited by 82hle, 02 May 2010 - 07:51 PM.

[Shifty]

Well, the project is snowballing nicely now!!

Its difficult just to try and give everything a quick fix when you get into it isn't it??!!

The next step is to pull the engine so you can check it and paint it nicely, or drop the front frame so you can get in and paint it all nicely.

Heh heh heh!!

[82hle]

Mini-update (geddit?!)
No pictures as not really pictureworthy, but progress to report.

Painted the door sills and fitted the doors.
Fitted the fuel tank.
Connected the fuel pipe at both ends, incorporating a filter at the rear.
Fitted hand brake cables - handbrake now works!
New (rear of front) subframe mounts fitted.
Laid battery cable back in place and refitted all the clips.
New output shaft seals fitted - had to pop the balljoints again.
Front shox fitted.
New selector shaft leakproof kit fitted.
Swept out all the debris from inside.

And a few other odds and ends.

Still a bit to do, Refitting carpets, seats, exhaust etc. but plodding steadily away at it.
Also a few bits still need painting - sills, valances etc.

Still need to buy some sill trim and a better grille, but I have snagged a set of "Cooper S"(not the official name I know) reverse rims, just need to pick them up.

Will be posting a wanted ad for a few bits, original bumpers that would be repaintable, a 82 style black grille, and a good set of 10" part worn tyres.

I'm thinking of running the reverse rims with the plastic hubcaps for the looks standard but not quite look - so a set of 145's would be favourite - as I don't want to run flared arches.


Mart.

[Shifty]

Reverse rims will look sweet with the plastic caps, a really subtle look( I like!!)

You can use 165 tyres without arches, assuming that the standard unspaced drums are fitted.

(have you painted the rest of the car yet??)

[82hle]

Just popped in from the garage - IT'S ALIIIIIVE!

MOT booked for next Wednesday - will update with more details and pictures later.

Shifty - you may still be owing me 10p yet...

Mart.

Edit - just spent the last hour and a half getting the indicators working - traced everything through - power at flasher unit - nothing going to indicator stalk - checked the manual - the feed goes through the hazard switch. That had bad contacts inside - stripped the switch and cleaned them up and viola! Flashers now work!

M.

Edited by 82hle, 29 May 2010 - 08:06 PM.

[82hle]

Just lowered the car down onto the ground - it's been up on stands for over 3 months. I seem to be chasing small electrical problems due to bad contacts - previously mentioned hazard switch - then light switch - then fuse that feeds the side lights - then had to drill the rivets out of the horn and clean the contacts inside and that sprung back into life. Then everything was working except the brake lights - a strip and clean of the switch sorted that out. Just torqued up the wheel nuts and blew the tyres up to pressure. I added the car to an existing collectors policy, so all that remains before tomorrow's MOT is to extract the car from the garage - there's another car and loads of tat in the way.
Zero hour 2:15pm.
Wish me luck.

Mart.