Adoom Posted October 13, 2017 Author Share Posted October 13, 2017 Too many photos... But I had deleted a hole for the clutch master. Fortunately I made a template with a few layers of masking tape before cutting it out. BAM! And the rust is GONE! 1 Quote Link to comment Share on other sites More sharing options...
Adoom Posted October 13, 2017 Author Share Posted October 13, 2017 And also! I patched a hole in the A pillar. And I finally got around to putting some tacks on the rear of the tunnel seam. This is all I will do, it's seam welded all the way on the other side. And I noticed my Argoshield is on 'empty'. 5 Quote Link to comment Share on other sites More sharing options...
Adoom Posted October 14, 2017 Author Share Posted October 14, 2017 Fit you bastard! I need more clamps. Only one of these is mine, I borrowed the rest. Mole grips/Vise Grips are spendy as! 1 Quote Link to comment Share on other sites More sharing options...
Adoom Posted October 14, 2017 Author Share Posted October 14, 2017 After welding the cuts and cleaning up. Painted it with POR15. I'll sand it off in the weld areas and drill the spot weld holes when it's dry. 1 Quote Link to comment Share on other sites More sharing options...
Adoom Posted October 15, 2017 Author Share Posted October 15, 2017 I drilled the spot weld holes and cleaned up where welding is going to happen. I also added some holes so I can stick some more paint in the back of the seams once welded. And just in case, I added some drain holes. The original had a hole in the top, that let water in but no way for the water to get back out, so the bottom rusted out. 4 Quote Link to comment Share on other sites More sharing options...
Adoom Posted October 23, 2017 Author Share Posted October 23, 2017 Only took five attempts. The one on the right is the rusty original. 2nd from right is the closest I could get it. I made the up-bump on the bottom by bending it 90 degrees, then trying to un-bend it again. To do the folded over lip, I used a 8mm plate as an anvil and hammered the edge over, then kept hammering until I got it flat. I also made it long enough so I have enough for the other side of the car. 6 Quote Link to comment Share on other sites More sharing options...
Adoom Posted October 29, 2017 Author Share Posted October 29, 2017 So I thought, I'll just do an easy quick patch. LOL. Small holes Big hole Patch the edge of the .... filler hole bowl. Grind weld back. Weld in patch. Grind down welds. Realise I went too fast and hot with my welding, so it shrank and pulled the rest of the panel in causing a crease/dent down to the top of the wheel arch. I'd like to fix it rather than fill it because my straight edge makes the dent at least 5mm deep and about 200-300mm wide. I'm not sure of the best way to fix it... Cut a vertical slit through the patch and hope it relieves the tension, then weld the slit up much slower? I can sort of access to back through a hole big enough for my hand with a dolly. Could I panel beat it flat? Or is this too advanced for a beginner and it just get worse???? Help! 1 Quote Link to comment Share on other sites More sharing options...
Adoom Posted October 29, 2017 Author Share Posted October 29, 2017 I also made a start on recreating the end of the 'outrigger'. 2mm is so much more forgiving to weld. I made the shape by banging a block of wood on the end of the outrigger to leave an impression. Then cut along that line with a jig saw(I cut it a little too big, should have been smaller), so I ended up with a little block. Then I clamped the metal to the block in the vise and hammered it around the profile of the block. It worked quite well. The top flange is not quite right, I cut and shut/ trimmed it a bit afterwards, but didn't take more photos. 3 Quote Link to comment Share on other sites More sharing options...
Adoom Posted November 4, 2017 Author Share Posted November 4, 2017 BZZZZT BZZZT BZZZZT It took longer than you would expect to make this patch cause of a bit of a rib in the floor. 1 Quote Link to comment Share on other sites More sharing options...
Adoom Posted November 4, 2017 Author Share Posted November 4, 2017 I made the inner sill panel that closes off that big hole. But I didn't take a photo and now it's got wet paint on it. I also made the flange for the end of the outrigger. Quote Link to comment Share on other sites More sharing options...
Adoom Posted November 5, 2017 Author Share Posted November 5, 2017 Stuck the inner sill panel on. Feels much more solid now. 6 Quote Link to comment Share on other sites More sharing options...
Adoom Posted November 6, 2017 Author Share Posted November 6, 2017 I found a blog of a guy doing the same sill repairs and he has takes lots of photos which will help me reconstruct areas that had rusted into oblivion. https://rembunator.wordpress.com/2015/02/10/i-care-deeply-an-in-depth-look-at-the-front-end-sill-construction/#jp-carousel-169 4 Quote Link to comment Share on other sites More sharing options...
Adoom Posted November 9, 2017 Author Share Posted November 9, 2017 I got a sheet of 0.8mm cold rolled, cause @Spencer said it was nicer to weld. I think it was $50 something... I got a few things and didn't get the invoice back. Quote Link to comment Share on other sites More sharing options...
Popular Post Adoom Posted November 9, 2017 Author Popular Post Share Posted November 9, 2017 When the two guys pulled my sheet off the stack and put it in the trailer I saw double. I'm like "I think you might have grabbed two sheets there". Guy was like "If there are two, it's your lucky day". Just unloaded now. Must be my lucky day. Two sheets sticky stuck together with whatever oily stuff it is they protect the sheets with. Should have bought a lotto ticket. 10 Quote Link to comment Share on other sites More sharing options...
Adoom Posted November 13, 2017 Author Share Posted November 13, 2017 I welded this bit in last night. The welds are a bit shit, I think I had a bad earth on the ground clamp, but didn't realise till I was finished. 4 Quote Link to comment Share on other sites More sharing options...
Adoom Posted November 23, 2017 Author Share Posted November 23, 2017 Even being careful, I think I have managed to break the clips on just about every single fucking plug on my 1UZ. Quote Link to comment Share on other sites More sharing options...
Adoom Posted November 26, 2017 Author Share Posted November 26, 2017 Glued this bit on. I'll need to make a new jacking point before I can go any further with the sill. 4 Quote Link to comment Share on other sites More sharing options...
Adoom Posted December 11, 2017 Author Share Posted December 11, 2017 Made most of the jacking point. I still need to linish the welds a bit. no one will see it... but I will know. And sacrifice a big bolt, or something suitable for the stub thing. Mine is made from 2mm, the original is 1.2 or 1.5. I started off trying to use my bender... it's only rated for 1mm, I did one bend and realised it was damaging the edge of the clamping 'finger'. Dang. So I moved to the vice, a block of wood and a big hammer. 4 Quote Link to comment Share on other sites More sharing options...
Adoom Posted December 13, 2017 Author Share Posted December 13, 2017 Glued the jacking point in, then proceeded to grind off two of the new spotwelds while trimming to fit the middle sill panel. And the middle sill panel. I got the folds in the right place FIRST TIME! 3 Quote Link to comment Share on other sites More sharing options...
Adoom Posted December 15, 2017 Author Share Posted December 15, 2017 Then after much fettling I glued it in. And made the bit with the step in it to fill the gap. I made this in two parts otherwise I don't know how I would do the step. I didn't bother grinding the welds down completely, since they won't be seen, I did tidy some of them up a little. 5 Quote Link to comment Share on other sites More sharing options...
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