Update time, posting from my phone so forgive any typos!
New metal starts going in:
Closed up:
Jacking point was cut off of the piece of sill it was attached to as rust had got between the layers and blown them apart. It was rewelded to a new piece of steel:
The supports for the jacking point were fairly shot so I removed them, hammered one flat and used it as a basis for my cardboard template. This was transferred to steel:
And folded and zinc primed.
Then the bottom of the door post bit was cut off and a suitably curvy replacement had to be made, its OK not perfect, but better than the crumbly mess that was there previously. Annoyingly when cleaning it up after welding on I made a hole just above, so should have made it a bit taller and replaced a bit more in one go:
More CAD:
Jacking point welded in, shouldn't go anywhere I hope!
And primed:
And then I transferred my weetabix template to steel, went to tack it in and on the first one realised I had run out of gas! Doh!
So that's where things stand currently...
New metal starts going in:
Closed up:
Jacking point was cut off of the piece of sill it was attached to as rust had got between the layers and blown them apart. It was rewelded to a new piece of steel:
The supports for the jacking point were fairly shot so I removed them, hammered one flat and used it as a basis for my cardboard template. This was transferred to steel:
And folded and zinc primed.
Then the bottom of the door post bit was cut off and a suitably curvy replacement had to be made, its OK not perfect, but better than the crumbly mess that was there previously. Annoyingly when cleaning it up after welding on I made a hole just above, so should have made it a bit taller and replaced a bit more in one go:
More CAD:
Jacking point welded in, shouldn't go anywhere I hope!
And primed:
And then I transferred my weetabix template to steel, went to tack it in and on the first one realised I had run out of gas! Doh!
So that's where things stand currently...