The plastic spot welds on the rear bumper that holds the inner to the outer had broken on about 8 out of 10 so I gave it all a good jet wash and then once it had dried out used some Tigerseal to bond the outer skin to the inner structure. The two tabs that... Continue Reading →

First section of sill finally fully prepped. All of the spot weld points are matched to the original panel locations. New jack point plate welded on from the set of four I had made by the boys up at Aycliffe Fabrication when I worked in the North East. And welded in... This made it very... Continue Reading →

There has been lots of considered chopping out going on. There's been a fair bit of rust jacking between panels so I've been chasing creeping rust and cleaning it all out. More spot welds to drill out... Cutting back to the end of the creeping rust. At this point I've chased it all out at... Continue Reading →

The original fuel lines enter the passenger compartment and run through to the engine bay bulkhead. The two holes need to be blanked but were rotten and had to be cut out so whilst I was in the area working on the sill fabricated up the repair piece.

Getting closer to starting on the sill, need to finish sorting the floor out so there is a good reference to tie the sill back into. That means more floor repairs because where the floor panel joined the sill panel was not very healthy. Starting with this floor stiffener panel in the passenger footwell then.... Continue Reading →

Get 'em while you can. Been after a pair for ages. Mine have been over zealously tightened with an inappropriate tool more than once. And they keep coming loose. These are new(er) ones to go in that hopefully won't have the same issue. Right awkward job fitting them to the door mechanism. Yes I took... Continue Reading →

So to repair the sill on the car I need to repair the repair panel off a less rotten car. Adding hours into a job that could be avoided if replacement panels were still available. Each sill is a composite of 4 panels. I've already repaired and epoxy primed two, onto the final two. Split... Continue Reading →

Finished and primed the repair panel ready to weld on. On to the melting metal stage... Welded in and dressed the welds Pleased with that, time to get it in primer and move onto the sill work. And primed...

It's been a while but back on with this. Made an additional CAD piece to just make sure I had the curves and angles right after modifying the original CAD structure to map it to steel. Fabbed that up and ready to start welding it together and then to the car. The repair piece is... Continue Reading →

Did some Cardboard Aided Design work to design a chassis rail repair section. So much easier to do the fine tuning this way and then you can work out from this how to translate the cardboard into sheet steel and start working out the metal repair piece.

Did some more poking around at the end of the sill and the front wheel arch. Layers of steels and lots of corrosion. Plenty of opportunity to improve this mess. So let's chop out a load more crud and make some repair panels for this floor section. Bit of CAD and we have a repair... Continue Reading →