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MARTS-PL310 61 Datsun Bluebird Sedan


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Building the 1961 Datsun 310 Bluebird - RHS ‘B’ - Post Repairs/Build. Part One.

As it was in the beginning. Rusted, rotted from the inside out and battered with abuse.The abuse happened many years ago whilst trying the bend the pillar next to the front glass. I had placed lumber in the door frame opening diagonally then applied a hydraulic jack. before I knew it, the B-post base was collapsing and getting crushed. So i've a combination of rust and aft direction post damage on three sides to repair.
So, a flood of pics to follow, starting with the damage detail, rust repair of the lower flanges, opening up the inboard face panel by removal of the lower 10 inches, beating the damages back into shape, welding it all back up and grinding and sanding it all smooth.

2052020289_61BluebirdRight-B-Pillar-1.jpg.8145231751aa1115d48e9d124c4144b7.jpg

The underside and after detachment from the original structure.725411071_61BluebirdRight-B-Pillar-4.jpg.cb244960482bb647dfe5374996c550c5.jpg

558132310_61BluebirdRight-B-Pillar-6.jpg.b389a305dfffb9f7da2e4c366c91774d.jpg

As it mates on the new sill.
89789907_61BluebirdRHS-B-Post-3.jpeg.b5035e471a0f4e07416070b067833e98.jpeg

1997466288_61BluebirdRHS-B-Post-4.jpeg.b71b5e74476c622f88af2c3cb6b8378b.jpeg

The buckled inside panel with a heavy crease and rusted bottom flange.
76730474_61BluebirdRHS-B-Post-5.jpeg.33255d570df39d75eaf32c221e86a728.jpeg

Made a patch assembled out of three pieces and fitted it for the aft lower face.
1562310652_61BluebirdRHS-B-Post-6.jpeg.8203741d3fd66a94ca1a1c280aa167cb.jpeg

Similar for the front except made it out of one piece which took way too long to make.
Had to make a relief cut and weld in up anyway.
Decided it's better to stick with multiple pieces for a complex and tilted curved surface intersecting a vertical plane.
389586751_61BluebirdRHS-B-Post-7.jpeg.9a776dec008980c74401409e90f15007.jpeg

More welds added to plug the holes made from disassembly.
Backed it up with copper during weld to keep from making the holes bigger in the thin metal.
1379244459_61BluebirdRHS-B-Post-8.jpeg.76023d0a44614b17a21b46edbfffd5ac.jpeg

Underside now begins to look a bit cleaner.
2018034032_61BluebirdRHS-B-Post-9.jpeg.3743a356a23e805a2586f5d9a92c015b.jpeg

Cut the inside panel to gain access and make repairs to my prior mistakes of old.
1676345911_61BluebirdRHS-B-Post-10.jpeg.34ea99c3de227bc41ac6e78d7bf28411.jpeg

Innards.
2103037444_61BluebirdRHS-B-Post-11.jpeg.68037711faa9466f62148ec84101547f.jpeg

1242681207_61BluebirdRHS-B-Post-12.jpeg.5a21ec44506b241b40efb913f10c5798.jpeg

After panel beating the crease smooth, fitted up a patch to repair the rust.
154657661_61BluebirdRHS-B-Post-16.jpeg.7fb77259bf367cf2b86766a1e40199cb.jpeg


1833899702_61BluebirdRHS-B-Post-13.jpeg.4a13bc7ba9bfab68d5b8f56b2579c830.jpeg

1020240373_61BluebirdRHS-B-Post-14.jpeg.66418c1993bf7288285c699b86978d2a.jpeg

Then started tack welding it together.
1528726659_61BluebirdRHS-B-Post-17.jpeg.928320caa4faf8b7a34bd03af9d1e491.jpeg

Other side with my ugly series of tacks.
309635732_61BluebirdRHS-B-Post-18.jpeg.c98ce25a2ac25f40399f992ecb2d6b03.jpeg

Smoothed out the welds.
2066995358_61BluebirdRHS-B-Post-20.jpeg.80f8cd3ee083c8eea27be041efe56642.jpeg

1177190574_61BluebirdRHS-B-Post-21.jpeg.da5b274cf71244baa04e77a56d13c23a.jpeg

Removed the inner bits. Just needed a bit of cleaning and then weld back in.1183899155_61BluebirdRHS-B-Post-23.jpeg.bf2d2f3053306ffdfcfacf720b32ab10.jpeg

Surfaces inside the post were better than expected with lots of clean metal in places.
An easy cleanup in preparation for reassembly.
791338732_61BluebirdRHS-B-Post-24.jpeg.511d4b76b133ed459ec4854eba059f54.jpeg

1813037557_61BluebirdRHS-B-Post-25.jpeg.35a868330a0b91c0844ffc1c0a259819.jpeg

The abuse damages are fixed (beat flat) and ready for closure.
1835023732_61BluebirdRHS-B-Post-26.jpeg.74bf8ad9330038c325bb1f3dd765f898.jpeg

593201316_61BluebirdRHS-B-Post-33.jpeg.7136a067c561c3981b81f44ec30394a3.jpeg
A thin coat of copper primer for the insides.

(To be continued next post.)

Discussion:

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

 

Build:
https://oldschool.co.nz/index.php?/topic/60264-marts-pl310-61-datsun-bluebird-sedan/

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