273 replies to this topic

[Ben_O]

Pary of my panel order was delayed meaning I didn't have the floor pans to continue on from where I left off so I decided to sort the boot floor and replace the valance.

 

First job, remove the old valance

 

 

 

It's all pretty good under there with just some surface rust for the most part.

 

One closing panel is fine so will not need replacing

 

 

I'll just clean that one up.

 

The other side will need replacing as there is corrosion under the edge of it

 

 

So off with the old

 

 

And then after a clean up, I had to chop out sections of the back panel and boot floor to replace.

 

 

 

 

And then on with the new closer 

 

 

Next up, I prepped the new valance 

 

 

Clamped it on

 

 

And spot welded it into place

 

 

Cheers

Ben 

[Crazy]

Super work as usual Ben,

[Ben_O]

After a few days, the other parcel arrived containing thr floor pans so I cracked on with that.

 

Here is the new left front pan marked up for rough cut

 

 

And then cut and positioned in place

 

 

Next I marked exactly where it needed cutting to join the existing floor and then trimmed and clamped into place

 

 

And then tacked

 

 

I left a fairly big gap in the join as I intend to grind both sides flush after welding so need perfect penetration the whole way.

 

And here it is fully butt welded

 

 

And we have perfect even penetration the other side too

 

 

I gave it a grind up

 

 

 

And then drilled and plug welded the front edge to the toe board

 

 

Then I reclaimed the slinging bracket and welded that back

 

 

Then made and fitted a new carpet retaining plate

 

 

 

Job done.

 

Next up is the replacement step and outer sill.

 

Cheers

Ben 

[Fred&Rex]

Wow 

Amazing work going on, special set of skills, looking great, hoping mine might receive the magic soon.

[Ben_O]

Next step is the step.

 

First thing to do is cut out this section of quarter panel to give me access.

It needs replacing anyway.

 

 

 

Then drill and cut the step off

 

 

 

Then replace the jacking point 

 

 

 

Next up, I trimmed the step panel down to just oversize and laid it in place to mark my cut lines

 

 

Then cut and welded

 

 

 

Then spot welded the rest

 

 

After that, I made up a new section of quarter panel to close off the previously opened up part

 

 

And welded it in

 

 

 

 

Next job will be the outer sill and lower flitch repair.

 

Cheers

Ben 

[Ben_O]

Next I prepped and clamped on the outer sill

 

 

And then spot welded the top to the step and quarter panel

 

 

 

And then finished by plug welding the bottom edge to the inner sill and jacking point

 

 

 

That just leaves the flitch repairs on this side now

 

[Ben_O]

All these small repairs start off with a card template

 

 

Then transferred to steel

 

 

Before being welded and dressed back

 

 

[JXC Mini GT]

Great work Ben, another masterclass of how to repair your Mini.

[Fred&Rex]

Loving these repairs…

[Crazy]

holy smokes quite an update today Ben, such a magician with all these little bits, great seeing the step by step photo's 

[slidehammer]

Great work as always Ben, I always enjoy your posts very inspiring.

[Ben_O]

I made a start on the other side today

 

 

 

I cut the outer sill off

 

 

And then made a decision on how much of the floor pan I will replace.

Here it is marked out for cutting

 

 

And then cut

 

 

I then removed the lower section of flitch as it's a bit grotty

 

 

Then had a good clean up

 

 

Before roughly trimming the new section of floor

 

 

Here it is fully trimmed and clamped in place

 

 

Tacked

 

 

And fully welded

 

[colinf1]

Looking good Ben! Was there any numbers stamped on the lower section of the flitch to suggest it was the original inner wing?

[Ben_O]

Looking good Ben! Was there any numbers stamped on the lower section of the flitch to suggest it was the original inner wing?

Cheers.

There were no numbers stamped but also no evidence that its not the original inner wing.

It was all factory apart from the ugly mot patch 

 

Cheers

Ben 

[Fred&Rex]

Superb work as usual, credit to you Ben I couldn’t do what you’re doing..

Thanks
Daz

Nudge nudge, send me a cost for mine please!