Adoom

Adoom's 1976 Triumph 2500 TC

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Makin' a patch panel from a firewall I got sent. I dunno how much of it I will end up using.

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The pile of bits I spot weld drilled off.

 

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The hotwire I got from @pusherman  after paint stripper and water blaster and 400 grit. The original coating and lacquer are removed, but there is still a bit of the blue paint that was all over it. WTF was that paint, it's nearly indestructible?? Still need to scrub a bit between the spokes to get rid of any loose stuff then mask it off and repaint the black bits.

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Removed the dash and the heater and that horrible foam rubber pad thing. Found the heat tap is seized, not sure if on or off, so had been disconnected.

Also, I think I will need to use that whole patch panel.

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All the rust is in that one panel as far as I can see. 

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The heater is pretty rusty too, and full of crap. Jeez it's heavy. Anyone got a good one they don't need before I try fix mine?

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Some clown hot glued the rear parcel shelf in cause the clips were missing. I scraped it off without too much damage. But the long thin metal bit that goes behind it was rusted through at both ends. Anyone got a good one?

Found some rust at the bottom of the left rear quarter window. Took it out to find a decent hole and a small hole on the outside that had been bogged over without bothering to remove the window first. Repair looks to be within my welding skill level, but part will be outside, so it will need to be painted. I wanted to avoid painting it for a while.

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Make that both rear quarter windows are rusty at the bottom. Jeez, the fuck is up with these factory gaps between the panels, it's like they designed it to leak into the guard if the mastic stuff ever failed.

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Looks like I will need to do some rust repair on the sills. :(

There is no rust on the outside/underside, though I still need to do a comprehensive search. 

So far... I can stab a screwdriver through the front left corner of the passenger footwell.

The front end of the drivers sill in the wheel arch has some rusty holes.

The end of the passenger sill in the wheel arch has some roughly tacked on patches. The front outer part of this sill has been repaired, but I don't know if they cut the rust out first or just slapped a panel over the top because there is a lap weld rather than a butt weld where the repair ends. The end of the sill in the rear wheel arch is rusting through around the seatbelt reinforcing plate.

This guys thread is most helpful to make it look less intimidating. http://retrorides.proboards.com/thread/173102

 

I'm supposed to be getting electricity in the shed TODAY! So I could use tools other than my cordless drill.

 

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IMAG5556.jpg.7a3be6ea9e00b30540961023f88accd4.jpg

Left rear quarter window rust

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Right rear quarter window rust

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Under the parcel shelf rust

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Left footwell/sill rust

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Right footwell/sill rust

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Right sill/wheel arch end rust

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Shitty looking patches on left sill end/wheel arch

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Rusty left rear seat belt mount/wheel arch

 

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I got power to the shed on Friday! Lights and powerpoints are coming on Wednesday!

My 1UZ had a hydraulic pump for the fan, wtf is wrong with an electric one?!?! I'm only running an alternator, so don't need any of the other idler pulleys.

If I just remove them, it leaves big holes exposing the timing belt. So I adjusted them with the hack saw and angle grinder to remove the bits I don't need.

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I also removed some brackets from this that were for the AC or PS pump. 

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This tensioner thing no longer served a purpose other than filling in a hole, so I cut the shaft off.

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Passenger sill. I can shove a screwdriver through this gap.

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I removed the dodgy patch welded on with bird shit. And....

 

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To get behind the guard I'm going to do something that scares me a little.

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And then...so the guard has been damaged in the past, beat back into shape, then skimmed with about 6mm bog. 

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Balls, more rust up there.

Bye bye guard.

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I need to make another one of these.

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I need to replace part of this gutter, and it needs to come off so I can fix the rusty thing under it.

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Most of this thing needs to be replaced... there is also a small hole behind it that has been bogged over.

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I've looked further down the guard and didn't see any more horror.

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I got the channel off.

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This is rusty.

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These are bits I have cut off and need to use to make templates for repair pieces.

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Cut that off. The inner wing panel behind it also need to be replaced, it's pretty thin in lots of places.

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An outer sill was BRAZED, over the old rusty sill, so that will have to come off too.

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Need to make a new end for this box section thing.

 

Still more cutting to do before I can start putting new metal in, getting a bit hard to fit the grinder in... Might have to switch to the reciprocating saw. Maybe the plasma cutter, but I'm wary of cutting through more than one layer.

 

I would like to replace the rear half of the wing/guard as mine is full of bog. Anyone got anything? Front half of the guard appears to be okay,

 

 

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Got a couple more axle stands to use at the back. Couldn't find any as big as the ones I had at the front....

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It will wobble a bit if I push on it, but I think it needs to wobble a fuck ton to actually fall off.

 

Cut some more bits off.

 

 

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I can/could start making repair panels for the top of the guard now and start putting metal back in.

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Welded on a tiny patch.

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Got pretty good penetration.

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Unfortunately my dog is shit scared of the noise of mig welding and goes to stand in the furthest corner of the garden and pants like crazy. :/ I have to use treats to get her to come back.

So I feel bad when I weld and don't get much done.

Hopefully it's better when the house is done and I can put her in there where she should not be able to hear the welder.

This patch is next. I need to drill some holes in it, for making spot welds, first.

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Then I make the big patch that goes behind it. Shouldn't be hard, it's just a rectangle with a bit of a curve.

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Reposted all my photos in this thread loading them up to OS for hosting. 

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Welded the rest of the patch in after turning down the power to stop blowing holes. Need to sand down the welds and make the box section thing that goes over the top of this.

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The dog went to the vet for a few hours, so I took the opportunity to make the scary grindy noises.

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Cleaned up the welds enough so the next bit can go on top.

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Cut back some more of the box section as it was quite rusty on the top. Not quite sure how to repair the rain gutter, it's quite a complicated shape where it meets the top of the guard and it has to be just right for the trim to clip back on. Ideally I could cut one off another Triumph that isn't rusty there, but I suspect that most of them are.

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Ground back the big ugly welds down the A pillar, that had held the ....closing plate??...on.

IMAG0004.thumb.jpg.3186eccd365a23e3947ae3b5c3ce9e8d.jpgAnd the dog is back. She had to have a broken claw removed. She was still half cut from the sedatives. 

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I am having a 4 day weekend. So... instead of doing my laundry yesterday.

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The bits of wood spread the load enough that nothing bent. Most of the weight is on the strut towers.

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And out. Much easier to access the rusty firewall now.

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There was just enough room to roll it out from under the car, I had to take the gear lever off though.IMAG0014.thumb.jpg.ecb4c28493e51b3fbe6af7407bdfb7f4.jpg

Anyone want to buy the engine and gearbox? It ran alright when I drove back from Auckland. Gearbox wasn't crunchy and it stayed in gear. Overdrive works. I don't know when it last had an oil and filter change.

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Since the engine was out... And it's the last day of my 4 day weekend. I thought I'd remove the rusty firewall.

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I still need to remove this bit, I couldn't get in with the spot weld drill, so I just cut it off.

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The air box thingy for the heater was rusted up the sides too. Fortunately my donor panel does have those bits, but not all of the air box thingy, so I will have to weld it together.

IMAG0028.thumb.jpg.287e3806011c883b191b1dd125564348.jpgAaaand the donor panel. The edges need some hammering to straighten them out. I'll need to  drill out all the circled spot welds to remove the top panel so I have access to weld this to the remains of the air box thingy. I'm considering changing the bottom flange so it's not a shelf for water and crap to sit on. I would bend the end of the tunnel up, to make a flange and cut the flange off the firewall. It will also give me a tiny bit more clearance off the back of the engine.

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