MARTS-PL310

MARTS-PL310 61 Datsun Bluebird Sedan

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The left side Bluebird rust damage survey. Right side is about the same except much less damage to the front fender and more damage to the 'A' pillar or post.

Starting with the left front fender and working back to the rear dog leg and side of rear seat floor. And a then preview of the right side.

 

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Build of the lifting jack structure

 

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Original outer sill panel where the lifting jack pipe was

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Inside the sill are the remnants of the jack bits

 

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Made a forming die to recreate the indented outer shape, test looked good on scrap piece so went ahead

 

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Simple as sandwich the panel and tighten the bolt

 

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Looks not too bad!

 

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Closer examination. The extra metal around the bolt hole gets trimmed out to match original. The lower pop out section (to left) is welded on and then cut off. Wrong position darn it ;(

 

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Straight on view after trimming

 

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Moving on to recreate the inner vertical stiffening brackets. Takes a bit of imagination since only about half of the originals remained

 

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Bits getting ready for weld

 

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Checking bits out for fit

 

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Sand blasted the original pipe free of rust

 

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Now really ready for weld

 

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Welded and checking results for fit against inner sill

 

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Coated with POR 15 for future rust protection. Turns out this coating can catch fire real easy and sustain flames.

 

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Next are the three outer sill segments to be welded together. I've kept a lot of extra flange widths, top and bottom, to resist warping. These flanges gets trimmed back to about 1/2 inch.

Discussion:

https://oldschool.co.nz/index.php?/topic/60267-marts-pl310-61-datsun-bluebird-sedan/

 

Edited by MARTS-PL310
annotate pics
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