Further Repairs

So after some careful planning, I chopped the engine bay side of the N/S chassis rail, carefully doing so to allow repairs without needing to setup a jig. There was plenty of structural rigidity in the sections of rail left and the rotten sections simply lifted out once they were cut out – once the spot welds were drilled out, most of the work was done with a 1mm slit disc and then some careful work with a dic on the Dremel.

Made up a repair panel and fitted it after I had pressed in some creases to match the original section.

Most of it could be welded from the engine bay side, but some work had to be done from inside the rail.

Then fabricated up a repair section for the gearbox mount support. Slightly more complex as this has a M6 nut welded on to act as an earthing point. It was also an excuse to get a hole swager out…

Dressed down the welds with a combination of grinding disc, flap disc and carbide burrs.

Next job is to fabricate the internal gusset and the chassis rail top and get them fitted.