S3 109 Safari project......

GSF 109 · Dec 17, 2022

I was really concerned that the vent flaps would be unusable, but amazingly they started moving with a little encouragement. They will clean up just fine but that’s a job for later. I popped them off the retaining clips to see what repairs are needed. Looks quite overwhelming but I think I will take it a section and a time and see how it goes.

GSF 109 · Dec 17, 2022

As it was going relatively good so far, I measured up the repair panel size and cut some steel to make one section of the repair first. I bought a small sheet metal folder at the Sunday market, and this was my first time using it. Don’t know how I managed without it to be honest!

After folding the panel, I placed it over the corroded area, marked it out and cut the rot out.

GSF 109 · Dec 17, 2022

Now that I was on a roll, I thought I would weld it in which was a bit tricky due to the thin material. I turned the amps down and it came out okay. Not MOT standard but it doesn’t need to be.

GSF 109 · Dec 17, 2022

The next bit of fabricating will be making the repairs to the duct area. You probably noticed that I never cut the hole out for the vent flap. The plan is to do that when it’s all welded up as it will be stronger by then and I can use the other dash as a template. Will get on with that the next day I’m in the shed.
I wanted to fit the windscreen as it was getting in the way. I had to buy 2 new hinge pivot bolts which were genuine landrover with the corresponding price tag!

Good to see it on as it’s starting to look a bit more like a landrover

Wagon Loon · Dec 17, 2022

That's coming along nicely,
I got some closed type self adhesive foam to replace the foam seal covering the flaps. But I still can't upload an image ?

GSF 109 · Dec 17, 2022

Wagon Loon said:
That's coming along nicely,
I got some closed type self adhesive foam to replace the foam seal covering the flaps. But I still can't upload an image ?

Thanks, it’s good to make some progress for a change! I now copy and paste the photos now and it seems to work for me.

Wagon Loon · Dec 19, 2022

I'm just using a mobile phone, and a big red no you can't sign whichever way I've tried. It says I don't have permission to add files to Wagon Loons topic/thread. Actually is say's "
The following error occurred:
You do not have permission to view this page or perform this action." if I try to add anything not text.
So I assuming my profile didn't get my thread's attributes moved with it completely not even the silly faces (⁠╯⁠︵⁠╰⁠,⁠)

GSF 109 · Dec 21, 2022

Wagon Loon said:
I'm just using a mobile phone, and a big red no you can't sign whichever way I've tried. It says I don't have permission to add files to Wagon Loons topic/thread. Actually is say's "
The following error occurred:
You do not have permission to view this page or perform this action." if I try to add anything not text.
So I assuming my profile didn't get my thread's attributes moved with it completely not even the silly faces (⁠╯⁠︵⁠╰⁠,⁠)

Yes, that’s the same message that I get. Don’t hit the ‘upload a file’ button. All I do is type in the text box as normal, copy the pictures from my photo stream, then paste into the text box. They will go in full size. Hope this works for you.

GSF 109 · Dec 26, 2022

Okay, so moving on with the dash, I drilled out the spot welds on the flat section then cut it off past the rust damage to get to sound metal. This allowed me into the two corners which are also missing due to rust…

GSF 109 · Dec 26, 2022

After cutting out the left hand corner, I used some CAD (cardboard aided design) to cut and shape a replacement section. Once aligned and welded in it looks much more sound.

GSF 109 · Dec 26, 2022

Moving onto the right hand side, I cut out some more cardboard to make a template. This was a bit more tricky as it curved in two directions with a flange. Nonetheless, it seemed to fit okay. Once welded, I ground the welds down to make it a bit more neat. I gave it a quick coat of primer, as the next thing to do was to create a return lip for the vinyl something to clip to. As you can see by the other side it’s not exactly the same but it will do fine.
Once completed, I cut out a closing panel section from fresh steel, drilled some holes for plug welds to replicate the original and welded it in after measuring the overall width first and comparing against another dash.

GSF 109 · Dec 26, 2022

I thought I would have a go at reinstalling the dash vinyl to see how it all sits together. To be honest it needs some tweaking, but it’s not too bad. This also gives me the opportunity to shape the curved section of dash and get it as close as possible using the dash as a template.

GSF 109 · Dec 28, 2022

I’m starting to see the light at the end of this particular tunnel now. To make the curved section, as I don’t have a shrinker/stretcher tool, I thought I would bend up some thicker gauge steel and put some slots in to make the curve much easier. Once I got it about right I welded up the slots, sat it in place and tacked it in. After some tweaking to get the flange parallel with the rest of the dash, I cut out the remaining rust on the curved section.

GSF 109 · Dec 28, 2022

After making up yet another cardboard template for the remaining section, once cut out, it took a fair bit of fettling to get it to sit properly. After tacking in position, checking yet again, I fully welded and dressed off the welds. Now that it’s sound, I’m thinking that I may put a skim of filler over the repair just to make it a little smoother. Probably overkill, and not strictly necessary I know.

GSF 109 · Dec 28, 2022

While the dash was sitting in position I marked around the vent flap hole and drilled the screw holes. Next time, the plan is to square up the hole, cut it out and fix in the locating tab for the rod. While I was tidying the welds, I noticed a small fatigue crack, so gave it a couple of tacks. That will repair it and give it a bit more strength.

codfather79 · Dec 29, 2022

Coming along nicely.
cardboard aided design, I like it

GSF 109 · Dec 29, 2022

codfather79 said:
Coming along nicely.
cardboard aided design, I like it

Many thanks. I feel as if getting this lower dash done is a major milestone as there is so much additional work required on it that I was never expecting to do. Gotta love Landys!

GSF 109 · Dec 30, 2022

Had a bit of time today to do a bit more to the dash. The next thing to do was to cut out the other vent flap hole. I made a template from the other side and copied it over. I drilled four holes then used the cutting disc to cut it out. After that I salvaged the small bracket that the flap pivot rod fixes to. Unfortunately this area was completely rotten before replacement so I had no point of reference to fix the bracket. I’ve positioned it as close as possible to mirror the opposite side bracket, so should be fine.

GSF 109 · Dec 30, 2022

It wasn’t until I welded the bracket in that I noticed the small bridge that provides the pivot point for the spring was missing! Rather than drilling one off from another dash, I made one from some 0.5mm steel and tacked it on. After a quick trial it seems to be spot on.

.

GSF 109 · Dec 30, 2022

While I was cleaning up the metalwork for paint prep, I discovered yet more welding required.

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I cut it out as per usual and patched some fresh steel in. Hopefully that is the last welding required on this dash panel!

S3 109 Safari project......

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