4 replies to this topic

[Danny-T]

Okay, I've had a good read through and search of the forum and not found a great deal on this.

I've been sorting out the running gear of my 92 spi Cooper and time is fast approaching to tackle the rot that's set in!

I've just purchased a 100amp gas/no gas Clarke welder (impulse purchase due to a VAT free day at my local machine mart ).

I've tried looking for welding lessons in the area (Bournemouth/Dorset) but have had no luck with term times (everywhere starts in Sept or "when numbers are full"). Anyhow, I've found a few online vids and tutorials and will pick up a load of scrap steel and teach myself. The actual act of welding I'm not too worried about, it's the mini specific stuff I could do with some help with. (Nice bit of background for everyone - not exactly sure why i felt inclined to make this my bodywork life-story, sorry!).

There's a fair amount of rust in the following places:
Near side A-Panel
Both Wings
Windscreen Scuttle
Near side Sill
Rear quarters
Battery Box
Who knows what else i'll find :S

I'm not too worried about finding more as I am in no rush to get this on the road and prepared to take my time to get it right.

So, onto my actual questions:

1 - How's best to decide whether to patch a panel or replace? Things like the wings are too far gone so that's an easy one but other panels just have a few spots here and there or just a small patch of bad (hole right through) rust.

2 - I've never removed panels before, I've read it's generally a case of drilling the spot welds, are all panels likely to be spot welded in place? After drilling I can't imagine for one minute the panel will just effortlessly come off, any other considerations/advice?

3 - Am I best to remove all the rotten bits first and then piece it all back together or tackle removing and replacing/patching one panel at a time?

4 - Is there a best order of events to do things?

5 - The car is kept outside (no garage) am i flogging a dead horse or will a vented cover surfice?

6 - In light of the above once i've stripped, removed and replaced metal, what should I slap onto it for short-term protection until I'm ready to prep & paint?

Sorry for the mass of questions but as I said couldn't find answers to all the specifics, hopefully this will end up being useful to others too.

[mini_kev]

ok here go's......



1. Where possible if it isn't too much more work its generally worth replacing the whole panel, as it will genererally give a much stronger and better looking finish than patching everwhere. Sills and battery box arent the hardest of panels to replace so probably worth replacing, chances are if it needs patching and you do it it will rust through from another place along the sill.

2. When you drill the spot welds dont drill all the way through, drill halfway through then it should come apart.if it doesnt then using a flat chisel slowly hammer it down the the joins of the panels, once drilled the spot welds should break quite easily. The panels wont just fall off but its usually pretty easy to see whats still holding them on and usually just a case of going at them with the grinder in places until they come free.

3. Hmm difficult question..... usually best to concentrate on one area at a time as cutting large parts off will obviously weaken the shell. Id say with the information you've given then take the two wings and a panles and scuttle off, replace all that but line all the panels up 1st before starting to weld to ensure you get a good fit of ALL the panels, it no good getting a perfect fit on one side only to find i means the other doesnt fit properly if you get what i mean! Quarter panels and sills could then be done one at a time.

4. Not much of an order but obviously scuttle should be done same time as wings as once you've changed the wings you won't be able to do the scuttle without damaging the wings again!

5. Many a good restoration have been done outside on the drive. Just dont leave any bare metal after cutting and grinding or it will begin to rust very quick.... best option iv found is a zinc based welding primer. Spray it onto the bare metal and it keeps the rust of excellently. Try and keep it covered if you can especially if you've taken the glass etc out.

6. Think i just answered this in the previous bit.

Hope this helps and good luck with the project.

[Danny-T]

Thanks mini-kev great tips, will report back with progress - which I imagine will be slow now the weather's turned and the poort thing's outside

[mini_kev]

No problem mate, I know how you feel, mines currently stuck on my drive at home while im at uni so haven't been able to do anything for ages!!

[ratty]

1. Its easier but more expensive to replace whole panels but if you do decide use genuine panels as they fit better

2. Use a spot weld drill bit as its easier to get the panels off without destroying the edge you wish to leave in place

3. Dont remove too much structural metal or it will sag

4. Remove the front first, fix the sills and floor, then the rear and finally put front back on. This will keep it light and save potential damage to new front wings if rolling it over

5. See my rebuild thread on the brown bomb and buy a gazebo

6. Etch prime bare metal (cans will do) unless you want an Orange Mini