bloody beautiful mate. I got that all coming up. As soon as ive got a few extra pennies i'll get on the wheel arches, opefully with gas

ill get some piccies of the horrors i uncovered with the boot floor and i have a boot pan ordered and on the way for tuesday :D:D:D
 
well this is an undertaking to say the least ive been doing 10 hour days since saturday and it seems like im getting nowhere fast

firstly the sills ive replaced with scratch built pannels



 
one thing ive learned is never take a boot floor pannel out unless yer either sure about what your doing or absolutely mad



i hope its the latter of the two as i managed to knock this up for less than £2 worth of sheet steel
 
and a quick piccie of the home made body mount i made from an old catnic lintel rather than fork out £35 for a new one

 
Nice job Johnny. I hope you got it cheap,cheap , like £50 :D Whereabouts in Manchester are you ? Im in Reddish. Looking for a couple of lengths of box to do me sills. :eek:
 
impressive work there mate. You should stick em all in a single post of your own so ppl can admire your work. This thread only attracts a certain level of attention. Some mighty fine fabrication work there!
 
im at the same stage now, boot floor out and about to cut out crossmember too.

i took the silly route and spent about 200 quid on new boot floor and side panels and the 4 strengthening beams - i laid them in and they hardly fit anyway, should have made my own sides up like you instead :(

anyway i got them now so will have to use them/ make them fit

quick question - how did you get the strengthening beams off the bottom of the boot floor?

not that i need to cos ive got new ones but was just wondering how to reattach them - weld on or are they just bonded/stuck/rusted on?

cheers, and great work btw, ive just been looking at mine for the past few days thinking why oh why did i start this job :D
 
Can you use 75 x 50 3mm wall. I can get it in 2m lengths £15.57 + vat.60 x 100 is 5mm wall and goes up to £ 35 + vat per 2m length :eek:
 
Thats what i used mate. Just dont cut off too much material, if you weld if the the floorpan you will lose 25mm off of the standard sill depth and your A+B posts wont line up. Leave about 40-50mm drop from the floor and overlap some original sill over the box section so that the box lines up with the posts
 
im at the same stage now, boot floor out and about to cut out crossmember too.

i took the silly route and spent about 200 quid on new boot floor and side panels and the 4 strengthening beams - i laid them in and they hardly fit anyway, should have made my own sides up like you instead :(

anyway i got them now so will have to use them/ make them fit

quick question - how did you get the strengthening beams off the bottom of the boot floor?

not that i need to cos ive got new ones but was just wondering how to reattach them - weld on or are they just bonded/stuck/rusted on?

cheers, and great work btw, ive just been looking at mine for the past few days thinking why oh why did i start this job :D

Sorry for double post



They are spot welded to the boot floor, either drill em out or get a grinder on the welds. Do it from say left to right and it will gradually pop off
 
Last time I drilled the first couple of spots out then air-chiselled 'tween the pieces,bloody noisy,because....after doing a couple of inside weld repairs I noticed that I was getting sparks burnt into the window glass from all the grinding,and cutting before I even got to the weld-spit.Tried masking off but hot metal flies through paper and sets fire to blankets.Even using fireproof welding blankets meant I ended up working in a dark box cos I had covered all the windows!
So....slow speed drills and chisels, air if you got that luxury, leccy and gurt big 'ammers if'n you aint,innum jasper.....sorry,came over all cornish there,whoops
 
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Last time I drilled the first couple of spots out then air-chiselled 'tween the pieces,bloody noisy,because....after doing a couple of inside weld repairs I noticed that I was getting sparks burnt into the window glass from all the grinding,and cutting before I even got to the weld-spit.Tried masking off but hot metal flies through paper and sets fire to blankets.Even using fireproof welding blankets meant I ended up working in a dark box cos I had covered all the windows!
So....slow speed drills and chisels, air if you got that luxury, leccy and gurt big 'ammers if'n you aint,innum jasper.....sorry,came over all cornish there,whoops

invest in some thin polycarbonate roof sheets like on conservatory roofs wich yer can get from wicks or B&Q sparks wont go through it and it lets light in also if its cut to bout the right size so it just wedges in itll be reet ( polycarbonate sheets are pretty much the same **** that anti spatter lenses in welding masks are made of ) :cool::cool:
 
nice repair sections johnny,
as someone else said, you wanna stick em in a thread
o yer own, altogether.
best of luck to the op as his thread seems to
have been hijacked!
 
So ideally do I need 6o x 100 box or 75 x 100 box ?. I can't use 50 x 75 because the existing sills have rotted right back to the floor so nothing to weld too :eek: Is the length required 1400 ? Cheers.
 
invest in some thin polycarbonate roof sheets like on conservatory roofs wich yer can get from wicks or B&Q sparks wont go through it and it lets light in also if its cut to bout the right size so it just wedges in itll be reet ( polycarbonate sheets are pretty much the same **** that anti spatter lenses in welding masks are made of ) :cool::cool:

problem solved ! now to get some money.......;);)
 
hi guys going back to work tonight to attack the sills can anyone tell me what length there cut to please im using 60 x 100 shs 3.2 mm wall cheers
 
So ideally do I need 6o x 100 box or 75 x 100 box ?. I can't use 50 x 75 because the existing sills have rotted right back to the floor so nothing to weld too :eek: Is the length required 1400 ? Cheers.

I used 60x100 and slotted the top edge with a single 2mm cutting disc. Clamped together and then welded. This made the sills wedge shape wich fitted better up to the underside of the floor. Length is 1400mm.

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thanks mate i went down for a couple of hours and managed to finish one side so hopefully get down tomorrow and finish the other all fun and games
 

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