I didn't feel like getting grubby tonight and as I have some new shiney parts arrive, I decided it was best to fit the polybushes into them.
Why can't removing the existing bushes be as easy as fitting the new ones lol.
I didn't feel like getting grubby tonight and as I have some new shiney parts arrive, I decided it was best to fit the polybushes into them.
Why can't removing the existing bushes be as easy as fitting the new ones lol.
Good news, I'm starting to find some good metal to weld to now which is a bonus.
That's good progress mate. Just make sure you try and treat as much of that surface stuff you can see and shoot lots of cavity wax in there after it's all done
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Will do. Still a little more to cut out. I've got to weld in the new panels so cutting out a little bit more isn't an issue.Originally Posted by CrazySx
That's good progress mate. Just make sure you try and treat as much of that surface stuff you can see and shoot lots of cavity wax in there after it's all done
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Cavity wax will certainly be used. Wish I had done that when I first bought the car. Lol
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Don't we all!! I bought my car when it was only 5 years old. If I had shot it with wax when u bought it and every 3-5 years there after I wouldn't have had the rust I did. But I guess you live and learn
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It helps us have a new adventure of repairing the car at leastDon't we all!! I bought my car when it was only 5 years old. If I had shot it with wax when u bought it and every 3-5 years there after I wouldn't have had the rust I did. But I guess you live and learn
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Sheet metal bender Version 1.
Some 1.2mm sheet in there first.
The whole that needs filling in...........
That's not going to work.
So a bit more cutting away of the old metal needed. The lip has been completely removed now so I will not use the original profile at all.
That's looking better.
Quite neat, also means I can fully weld this to the good panel.
As you will see from this, the first attempt with the sheet metal folder version 1 was a disaster, far too many ripples to be any use.
Once I remake this piece I'll be happy with it as the fit is nice.
Quick check to make sure the bracket fits. I'll measure up the passenger side so it sits in exactly the same position.
Back on the car again today.
I first remade the piece from the other day with my new sheet metal folder. Much better.
I stupidly didn't leave enough for the bend to create the downturn lip for the sill......bollocks.
So back to square one. First, cut out the required size with plenty of ecess this time lol.
I then profiled it to the shape of the underside of the car which is a lot of trial and error. Then time to put the folds into it. Lots of measuring and checking before I folded the piece.
Perfect.
Just a bit of excess to cut off at the end lol.
Fits nicely to the underside of the floor.
Next up, I cut out some more of the outer skins to make a new piece to join them together.
Can't beat a CAD template
Cut out of steel, needs more fettling and tidying up plus some weight saving measures.
Fits nice and tight to the first panel.
Finally a check with the outer sill panel to make sure everything is lining up as it should. All good.
Nice use of cardboard
Who is welding all this?
I'm doing all the work.Nice use of cardboard
Who is welding all this?
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Top effort mate.
This look great Daz
Cheers chaps.
Start zapping
Yes captainStart zapping
Practice welds went bad. So borrowed Mark's welder and all went well. My welding certainly isn't the neatest but it's got good penetration and is solid.
New piece all made up.
and welded into place.
Fpmsl
Nice work Daz. People underestimate how hard it is to weld upside down. My welds were lovely on the bench in the garage. Upside down, outside on the floor was another matter altogether hahahahaha
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Tell me about it. Also, didn't realise there was a hole in my glove and one bit of weld went through. I've never taken a glove off so quickly in my life lol.
Also, only set fire to the seam sealer inside the car twice lol.
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The main thing is perseverance! It show your love and commitment for the car. The amount out cr4p that i inhaled during the process cannot have helped my health either hahahahahaha
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I'm certainly committed to this car lol. 9 years of ownership now.
The amount of dust on the car now makes we wonder what I've been breathing in lol.
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