361 replies to this topic

[stuart bowes]

a little glimpse of my highly technical methods of using a bit of card to trace the shape 

 

 

 

(cut and folded from 1mm sheet)

 

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also a correction to the above (oops)

 

 

to get 90deg the right way around

 

cut from 12.7 x 12.7 x 1.5 box section

Edited by stuart bowes, 11 June 2022 - 11:29 PM.

[stuart bowes]

some more ugly but solid welding (before grinding back)

 

 

this little corner is now probably far stronger than it was when it came out of the factory lol

 

tidied and primered, with the bolt hole drilled

 

 

waiting on delivery of more gas to get nut welded and move onto next area

 

in the mean time did a bit of investigating at the front end and as suspected nowhere near as rusty as the initial pictures lead us to think

 

 

pitted, for sure, but manageable we think

 

there is still the issue of the front valance, we might have to get a main front section panel (probably not heritage) and extract the lower portion from it, at the same time possibly think about options for losing the bumper and seam (still not sure if I like the look.. but it's easier to add a few brackets back on later than it is to remove in the first place I suppose)

Edited by stuart bowes, 13 June 2022 - 06:54 PM.

[Ben_O]

If you are going to purchase a new front panel to cut a section from it to repair yours, I would advise to just replace the panel entirely.

 

It's an easy job and with the old front panel removed, it's the perfect chance to de rust the mating flanges of the wings before fitting the new panel.

This is the best way of eliminating all rust here and preventing it from coming back in a few months.

 

Cheers

Ben 

[stuart bowes]

what we're really trying to avoid to be honest (and maybe it's less of an issue than i'm overthinking) is the front end getting out of alignment and never looking right again afterwards

 

if you take off the front main section is there risk of that or will the inner wings hold things sufficiently in place?

 

we could brace it I suppose (if needed) but so far it just seems like it's adding a lot of unnecessary work.  will know more for sure when we get down there and strip off more paint I suppose.  If it does need doing we'll just have to do it

Edited by stuart bowes, 13 June 2022 - 09:12 PM.

[Ben_O]

You are overthinking it.

 

With the front panel removed, there will be some movement but the wings will keep everything rigid enough.

As long as your bonnet fits nicely before hand, you can double check your alignment after claimping the new panel up but the position is governed by the teardrop mounts and the fit to the wings so you can't really go wrong.

 

Good luck with your decision.

 

Cheers.

Ben

Edited by Ben_O, 13 June 2022 - 09:20 PM.

[stuart bowes]

ah well cheers that's handy to know then if it comes to it

[sonscar]

I would second replacing the front panel.Cleaning up the wing flanges will handsomely pay dividends and there is much less welding than you at first think.As Ben says it just fits especially with the wings already in the proper position.Steve..

[stuart bowes]

I suppose it also makes access to the engine bay easier (with sub-frame off as well) so that's also one plus point in terms of effort saving

 

if as you say everything stays in the right place I'm much more inclined to agree for sure

[Ben_O]

 

[stuart bowes]

oh yes that would be much easier for tidying up the inner wings and bulkhead wouldn't it

 

I was actually dreading that, in the engine bay trying to get at all the awkward angles in there with tools etc.  there's the obvious answer then, just glad there's no alignment issues that was the only thing causing me concerns

Edited by stuart bowes, 14 June 2022 - 10:07 AM.

[elliot341]

I would second replacing the front panel. If the metal is pitted it's a lot thinner and the rust will come back or come thru your paint etc.

[MaximMini]

I would also recommend replacing the whole front panel since I know what it means to repair the original one with parts from a new panel .

[stuart bowes]

thanks again, definitely being taking into consideration

 

while I appreciate the advice can we take this as read going forwards please as I'm trying to keep the build diary fairly succinct and avoid it turning into a lengthy debate on this one minor issue ;)  I'm sure there will be at least one whole page of pictures on that bit when I get to it 

 

don't mean to be rude I just don't have a method of self-moderating the thread

Edited by stuart bowes, 15 June 2022 - 12:41 PM.

[stuart bowes]

rusty section of closing panel cut out

 

 

fabricated new section (1mm)

 

 

fettled to a nice accurate fit and added the flanges previously cut off for the attachment of outer sill (not welded in yet)

 

 

 

gap at nearest corner is not as big as it looks, the piece just needs a bit of a push to fit right, I'll give it a little twist before fitting

 

checked fitment as best as I could by clamping on outer sill and rear quarter and it seems to match up perfectly.. well I did do the same previously and take measurements so I was fairly confident it would

 

checked from rear side for complete closure (will require some final welding later on in the game when subframe is off for the easier access angle

 

 

trying to avoid just buying parts where not necessary, it's more fun that way ;)

Edited by stuart bowes, 15 June 2022 - 07:54 PM.

[sonscar]

I agree with repair where possible rather than wholesale replace,nice work,Steve..