It's been a while since I updated this thread, but I've been busy chopping and welding and had a holiday thrown in for good measure.
I decided to start at the front with the inner sill and floorpan repairs. Previously the floor pan had been dented in so I bashed it out, but I had no reference points as the sill was non existent so I had to do a best guess of where it went.
This first bit was tricky as it had a curved flange in the inside to connect to the floor.
I also decided that I wanted to keep the factory production line pressings, the front one was too far gone so I made a new one - the original bracket was plug welded on later.
Gradually working along the inner sill - here you see the indent for the front seat mount.
If ever anyone needed proof as to why we cut rot out before welding in new steel, here it is. You can see how the rust has transfered to the new metal.
Then there was this little lot to sort out.
I may have slightly cocked up the measuring on this one.
New jacking point fabricated.
Plus some repairs to the front one.
This is my press tool that puts the stepped edge into the sill section. It's made from ¼" plate welded together with some nuts and threaded bar for a pivot.
Here's the new sill in situ, stepped edge is underneath and replicates the factory spot welded seam even though I've seamed welded it.
Rear jacking point boxed in and the inner wheel arch repair started. Ready for the D post section to go back on (no photos of that)
Last bit to finish it off is the oval pressing on the front splash panel.
Last month I said:-
testrider said:
Just like on the telly for added peril :shock: and excitement
I've got a self imposed deadline, I really want it done for the Silverstone Classic at the end of July. :roll: :cry:
Well, I covered it in Epoxy Mastic yesterday and it looks great. I fitted the interior back in before breakfast this morning and dropped it off at the local garage for an MOT at 9:30. Just waiting for the phone call with (hopefully) good news.........