Project Rusty.

dieseldog69 · Oct 27, 2018

resto_d1 said:
Axle looks good though worst comes to worst I'll fit the remaining hub, diff and shafts. Very mindful how heavy it's getting now lol

Hernia alert

Nope, fit the hubs and tape some nice clean plastic over the holes and fit the bits into the casing once in situ, no point making it heavier than it needs to be

I think you need to crack on with the welding, the nuts and bolts stuff goes easy and although it does give a sense of achievement it is kind of superficial and if I were you I would concentrate on the getting the chassis sound and the body a bit further along before it bogs you down to the point where even looking at it pizzes you off, I speak from experience here mate, I spent so many nights until midnight welding and fettling away and after about 6 months of #progress I got to the point of thinking "I just want to sit on the couch and watch crap TV and not burning myself to bits tonight", if it wasn't welding it up it was bushings, steering boxes, wiring, shocks, brakes....... the list goes on.........

resto_d1 · Oct 28, 2018

I know I know

Once I start back on it I'll get on a roll Hopefully!

dieseldog69 · Oct 28, 2018

I should have bought one of these ESAB welding jackets years ago, oh to be laid under it and not feeling a thing as the red hot molten lumps are spraying all over the place LOL

Pics to come later, I'm not done playing yet, but the wind and sporadic rain has forced pauses here and there so I haven't got as much done as I wanted but it has been productive

dieseldog69 · Oct 28, 2018

Rain halted play far too many times today and I really didn't get much done, but progress is progress

Had to get the B post bottom built and welded up, not too shabby by the end, but first I decided to get rid of a straggler in the scrap department, get out the new spot weld cutting drills and the cutting fluid and away we go.

Got shot of that so on to the nice stiff card to cut out some templates to fabricobble the B post bottom.

Sliced, diced, tacked and seam welded in with a 10mm hole in the bottom for drainage

Wiped it all down with meths to clean off any residues and then slapped some primer on it

I did crawl under it and finish off the welding along the remaining inner sill to the new box section, got the cup brush on the grinder and cleaned off the burnt underseal and blathered it with primer too, I'll seam seal it all and then paint on a good coat of underseal to protect it all from rotting out again.
Still got to finish plating out the drivers side foot well after finding a bit more rot but so far so good and I will probably dive in one night in the week with the grinder for an hour, I will have to put a pause on the 6 O'Clock rule for noise and hope that the neighbours understand

The Mad Hat Man · Oct 28, 2018

looking good DD.

dieseldog69 said:
I should have bought one of these ESAB welding jackets years ago, oh to be laid under it and not feeling a thing as the red hot molten lumps are spraying all over the place LOL

I told ya

dieseldog69 · Oct 28, 2018

The Mad Hat Man said:
looking good DD.

Getting there slowly, oh to have a workshop once more

I am going to see if I can drill out the spot welds for the panels as it will be quieter than the grinder, the neighbours are grumpy again, he's on his period and her batteries ran I think LOLZ

The Mad Hat Man · Oct 28, 2018

does the ESAB protect yo ears?

dieseldog69 · Oct 28, 2018

The Mad Hat Man said:
does the ESAB protect yo ears?

No

But these do

The Mad Hat Man · Oct 28, 2018

Butt plugs?

dieseldog69 · Oct 28, 2018

The Mad Hat Man said:
Butt plugs?

Not sure what you put in your ears but........

The Mad Hat Man · Oct 28, 2018

andy/clark/dean...... pmsl

Chrisw8 · Oct 28, 2018

Looks good.
I haven’t drilled a hole in my b pillar.
I couldn’t see where water would get in it to need draining.......have I missed something ?

The Mad Hat Man · Oct 28, 2018

Chrisw8 said:
Looks good.
I haven’t drilled a hole in my b pillar.
I couldn’t see where water would get in it to need draining.......have I missed something ?

yes
condensation on roof.

Chrisw8 · Oct 29, 2018

Just had another look.

The post dunt go upto the roof on inside.........is confused.

resto_d1 · Oct 29, 2018

wherever it gets in it definitely does and sits hence why we have to replace them

Chrisw8 · Oct 29, 2018

Ok. Will have to drill mine then.

dieseldog69 · Oct 29, 2018

Chrisw8 said:
Ok. Will have to drill mine then.

The condensation comes from the door post and from the side windows (mines a 3 door) I like to have them open as it enables me to wave the wonder wand up there to spray in some cavity wax to slow down future rot

Easy enough job

dieseldog69 · Nov 3, 2018

Got out to play after work, then lunch

Didn't do much as I had a gas leak from inside the MIG torch so had to fix that first

Did cut another lump out of the floor though.

And then cut a bit of 2mm plate for the radius of the door shut that the door seal goes on and got that welded in.

Ground the splodgy bits back and dressed it with the flap disc and packed up as it didn't half get dark quick

Kiwi Jim · Nov 4, 2018

dieseldog69 said:
After getting rained off yesterday I found time today after running errands and doing chores.

Oh and I even managed to break out both welders

First I had to finish cutting a rather large chunk out of the A post bottom and remove what was left of the old front sill body mount, lots of cutting, grinding and sawing as I used the recip saw too.

View attachment 160375

Got the body mounts slapped on the outriggers and ready for the trial fitting of the box section to work out the cuts.

View attachment 160373

View attachment 160374

View attachment 160376 View attachment 160376

Pop the box in to measure it up.

View attachment 160377

Measure, cut and use some of the off cut for capping the ends.

View attachment 160378

View attachment 160379

Very pleased with the new welding leads and the clamps, top job and it's so weird using it now as the amps are unrestricted so I've had to alter my settings for the amps.

View attachment 160380

And this is the rear of the new sill with an angle in it that follows the same line as the wheel arch

View attachment 160383

It's currently sitting on the bottle jack, but it is in place and fits just like it should, ran out of time as I try to limit my noise to 6pm as the neighbours have small kids. The biggest setback was the fact that the MIG welder hasn't been used since I left Belgium, still had the bloody Euro plug on the end and needed a bit of TLC before I could even get it plugged in let alone strike an arc and then when I did get it ready and the gas rigged up I set about a scrap piece of steel to try and quickly get it set up for the task in hand, and.......... cue............ melting the wire into the tip and then spending almost an hour hunting down the spare tips and shroud, still can't find them and as it was late, and bloody dark I packed up and called it a day

Will nip into Machine Mart in the day tomorrow and get a pack of new tips and shrouds, probably get a tub of tip~dip and anti-spatter spray too.

More to follow in a few days.

Hi Dieseldog69, That box section which you're using to replace your sill. What would be its specificiations?

dieseldog69 said:
After getting rained off yesterday I found time today after running errands and doing chores.

Oh and I even managed to break out both welders

First I had to finish cutting a rather large chunk out of the A post bottom and remove what was left of the old front sill body mount, lots of cutting, grinding and sawing as I used the recip saw too.

View attachment 160375

Got the body mounts slapped on the outriggers and ready for the trial fitting of the box section to work out the cuts.

View attachment 160373

View attachment 160374

View attachment 160376 View attachment 160376

Pop the box in to measure it up.

View attachment 160377

Measure, cut and use some of the off cut for capping the ends.

View attachment 160378

View attachment 160379

Very pleased with the new welding leads and the clamps, top job and it's so weird using it now as the amps are unrestricted so I've had to alter my settings for the amps.

View attachment 160380

And this is the rear of the new sill with an angle in it that follows the same line as the wheel arch

View attachment 160383

It's currently sitting on the bottle jack, but it is in place and fits just like it should, ran out of time as I try to limit my noise to 6pm as the neighbours have small kids. The biggest setback was the fact that the MIG welder hasn't been used since I left Belgium, still had the bloody Euro plug on the end and needed a bit of TLC before I could even get it plugged in let alone strike an arc and then when I did get it ready and the gas rigged up I set about a scrap piece of steel to try and quickly get it set up for the task in hand, and.......... cue............ melting the wire into the tip and then spending almost an hour hunting down the spare tips and shroud, still can't find them and as it was late, and bloody dark I packed up and called it a day

Will nip into Machine Mart in the day tomorrow and get a pack of new tips and shrouds, probably get a tub of tip~dip and anti-spatter spray too.

More to follow in a few days.

Hi Dieseldog69, that box section you're using to replace your sill... what's its specificiations? (Sorry to have asked twice, I didn't think the first time had been posted... and while I can edit, I can't work out how to take one of them down).

resto_d1 · Nov 4, 2018

Your box will be vehicle specific mate. He's done a few and I think they've all varied in size. You got to measure up and get your box from there

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