Project Rusty.

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

Hernia alert :eek::eek::eek::eek:

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

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.

DSC00345.JPG


DSC00346.JPG


DSC00347.JPG


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

DSC00349.JPG


DSC00348.JPG


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

DSC00353.JPG


DSC00354.JPG


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

DSC00356.JPG


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 ;)
 
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 ?
 
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 :rolleyes:

Did cut another lump out of the floor though.

DSC00358.JPG


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.

DSC00357.JPG


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Ground the splodgy bits back and dressed it with the flap disc and packed up as it didn't half get dark quick :eek:
 
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 :rolleyes: 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.
Click to expand...
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 :rolleyes: 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.
Click to expand...
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).
 
Last edited:
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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