Patching I

Managed to grind down the welds on the repair patch that I’d fittedm but not finished off on the last bit of work.

Then the next tassk was making good the lower bulkhead lip that had been distorted by drilling the spotwelds and removing the rotten sections.

Then the next sections to tackle were the off side bulkhead seam joint where the top section was rotten and the lower section had started to go where the seam sealer had failed and with the seam sealer removed from the footwell you could see a seam of rust running along the joint. Top half chopped out and bottom half chopped to give a new edge. Patch tacked in place:

Ground down:

Top section that needs replacing. The rust is what was hidden in the joint of the seam. This is the repair job for tomorrow.

Finally I removed the last section of the chassis rail top. I had originally contemplated leaving this in place and welding the repair to it, but close inspection revealed it was pretty far gone. It was held in place by a spot weld that needed to be drilled from the footwell.

Once it was out I was glad it had gone after I saw the state of it!