Frosted
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Anyone know how to delete posts?
Last edited:
Rust repair bulkhead
- Thread starter Frosted
- Start date
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Evan farmer
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No
Frosted
Active Member
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- North of london
Here is the overside with the footwells I made welded in. Needs a bit of cleaning up bit I fabricated everything apart from the door pillar. The vent corners I made as well, will try and show how in a few weeks.
Landyfox
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Only words I have are... Incredible, amazing! Well done mate
Frosted
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Started to make the next layer which strengthens the corner of bulkhead and door post. Made a load of measurements then scratched head as could not remember how I did the other side.
I had left the existing metal of this layer around door hinge as I was going to butt weld the new piece to both layers of door post and the remaining existing metal.
Then thought I could probably make it out of one piece of metal to minimize cutting and increase the residual strength of the fabrication, so spent a very long time trying get existing layer of the door post. The spot welds were many and I have not found a efficient way of removing spot welds.
Anyone got a good way of doing it? I have tried all the different drill bits but found my self resorting to a cutting and flappy wheel, finishing up with a Dremel.
Then laid out the measurements with a bit of SohCahToa thrown to make sure the folds where in the right place after bending. Although at these small lengths and angles it was pretty minimal but just to make sure.
Cut out of 1.5mm steel.
Into the vice and bent it to 5° using the door as reference.
Then cut along to fold vertical section before it folds in following the door profile.
More bashing to get the last bend.
**Make sure you negate your sheet thickness from the length you want.**
Fits nice at the base just gotta do the upper fold next
I had left the existing metal of this layer around door hinge as I was going to butt weld the new piece to both layers of door post and the remaining existing metal.
Then thought I could probably make it out of one piece of metal to minimize cutting and increase the residual strength of the fabrication, so spent a very long time trying get existing layer of the door post. The spot welds were many and I have not found a efficient way of removing spot welds.
Anyone got a good way of doing it? I have tried all the different drill bits but found my self resorting to a cutting and flappy wheel, finishing up with a Dremel.
Cut out of 1.5mm steel.
**Make sure you negate your sheet thickness from the length you want.**
Fits nice at the base just gotta do the upper fold next
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ivancrx
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True dedication to a repair, nice to see.
Frosted
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Frosted
Active Member
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- 156
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I made the vent corners by cutting lines and pressing into a existing corner so to form the correct shape.
Then weld the cut lines that's the easy way!
If you have a shrinker that would work but I don't have one. I tried shrinking by using hand tools but its really hard need a lot of practice, patience and time none which I have.
You could also make a mold out of wood and try bashing the sheet down. I didn't try it but I would like to.
The rot is really bad over this side trying to keep as much as possible but welding to it is not going well its so thin I might have to replace a lot:-(
You can see the copper flat block I use to cool the weld down and use it behind any holes which form as the mig weld does not stick to copper so you can close the holes.
http://retrorides.proboards.com/thread/70135?page=1
Then weld the cut lines that's the easy way!
If you have a shrinker that would work but I don't have one. I tried shrinking by using hand tools but its really hard need a lot of practice, patience and time none which I have.
You could also make a mold out of wood and try bashing the sheet down. I didn't try it but I would like to.
You can see the copper flat block I use to cool the weld down and use it behind any holes which form as the mig weld does not stick to copper so you can close the holes.
http://retrorides.proboards.com/thread/70135?page=1
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Frosted
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So after much frustration manages to replace corners on both sides also area around inside windscreen holes.
As you can see I had to cut out much more rot and start again as it was much worse and I could not weld as was too thin.
But hey sorted now bit took much longer than expected as had to hack away each time.to find good metal.
Got to make this front piece now!
As you can see I had to cut out much more rot and start again as it was much worse and I could not weld as was too thin.
But hey sorted now bit took much longer than expected as had to hack away each time.to find good metal.
Got to make this front piece now!
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IamRobbie
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Well detailed I wish I had these kind of skills
Frosted
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Frosted
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This side has been much harder than the other side but nearly finished! Just got to weld it in.
Retroanaconda
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Nice work!
Frosted
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Finished off welding in the corner, welder is on it's last legs I spend hours stripping fixing and rebuilding it every time I use it these days.
Started on the bulkhead foot, made a jig clamped onto the outrigger. Spent forever drilling out the spotwelds.
And who would believe it the crappy replacement foot does not line up with original door pillar holes!
Should I name and shame?
Started on the bulkhead foot, made a jig clamped onto the outrigger. Spent forever drilling out the spotwelds.
And who would believe it the crappy replacement foot does not line up with original door pillar holes!
Should I name and shame?
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Frosted
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Or did my jig move, I guess I need to put the door on and see what's going on.
Anyway I need to start thinking about galvanizing anyone recommend company near Hertfordshire?
Anyway I need to start thinking about galvanizing anyone recommend company near Hertfordshire?
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Awesome work.
Pleased your galvanising it. All of that work should be protected.
Pleased your galvanising it. All of that work should be protected.
Frosted
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Sorted out the foot and welded It into place. Appeared my jig had slipped so put the old foot back on and aligned the holes i had drilled out for the spot welds. Re tightened jig and replaced new foot, not exactly the same but nothing a file didn't fix.
After that I spent an age getting the foot well to fit lots of banging and clamping and started welding it in. Looks like it will be a good fit. Drilled out all the holes ready for plug welding tomorrow.
Next on the list will be on to the drilling out all the holes and refitting everything to make sure it all fits before the galvanizing. Still no idea where or how I will do that!
Any recommendations of galvanizers company in the East Anglia area?
After that I spent an age getting the foot well to fit lots of banging and clamping and started welding it in. Looks like it will be a good fit. Drilled out all the holes ready for plug welding tomorrow.
Next on the list will be on to the drilling out all the holes and refitting everything to make sure it all fits before the galvanizing. Still no idea where or how I will do that!
Any recommendations of galvanizers company in the East Anglia area?
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Frosted
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Super scorcher today!
Wife busted her ankle last Saturday so didn't get to weld on Sunday so got to suffer in a tin roof cramped garage playing with hot metal.
Got footwell positioned and welded in and ground down the plug welds.
Welder is really not happy it does not feed out wire smoothly dunno what else to do to make it work. I have spent all my money I budgeted for the repairs and didn't expect welder to fail. Its still kinda usable but really frustrating any suggestions greatly appreciated.
Time for a well earned beer or six
Wife busted her ankle last Saturday so didn't get to weld on Sunday so got to suffer in a tin roof cramped garage playing with hot metal.
Got footwell positioned and welded in and ground down the plug welds.
Welder is really not happy it does not feed out wire smoothly dunno what else to do to make it work. I have spent all my money I budgeted for the repairs and didn't expect welder to fail. Its still kinda usable but really frustrating any suggestions greatly appreciated.
Time for a well earned beer or six
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Hats off to ya. Crackin job and super skills, welding and geometry!
mick the builder
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i used to live in N19
