Hi Glen, You are absolutely correct, i think the grinders i have are 115mm but the strip discs i bought are 100mm. I will check for sure tomorrow. I knew they were smaller discs but didn’t think they wouldn’t fit. I have been scouring my ebay and amazon accounts to find where i bought them. I eventually found them on my ebay account. I paid £26.99 for ten so will need to try and recoup some of my outlay. I never get on well with metric measurements, they didn’t have them when i was at school!! All the best, Norman
Todays progress was a bit slow. I made two reinforcements that go between the main crossmember and the floor. This is the bits made and fitted.
Next bit was the ends of the crossmember to the sill, i did this in three parts. I started to clean up the welds on one side And have the other to do.
I then cleaned up the old welds on the gearbox mount crossmember and rewelded them. I was about half way through this when i lifted my welding mask to check the weld and some piece of debris sparked up and stuck to the side of my eye lid, i had to pick that off, it is still nipping!
I them moved onto tidying some of my previous welds on the floor which look a lot better now.
Lastly today another mishap, when i was welding the floor i had the shell sitting (Careful how you say that) at about 45 degrees to make access easier and there was a bang and the shell moved and went off balance. I had a look and the front panel had torn where i had the rotisserie fitted. I quickly fitted a piece of angle and reinforced the area. I thought it might have collapsed and dumped the shell on the floor. That would have been a disaster and probably would have seen me give up. Tomorrow is another day and i need to have a grinding session but am aware of the neighbours. Hopefully they will be back to work soon and i can get on during the day. That’s it for today, i did forget to measure my grinders to check what size they were, anyhow feel free to comment etc. Norman
I have a cheap 'finger sander' that works well for dressing welds, much quieter and less aggressive than a grinder but takes material off at the same rate, mainly because it's much easier to be precise with it. Sterling work and a great thread!
I have a power file i use sometimes. The belts i was using used to break easily, i have bought better belts (German ones) which don’t break but seem to shread the grit quite quickly. The belts aren’t cheap and you can get through a lot of them, i have come to the conclusion that i must be tight, i look at stuff now and think “how much”. I had thought about an air powered file but don’t know anything about them. Does anybody have any recommendations? Norman
Todays progress, well i say today’s but it’s actually a couple of days progress. I started on the rear valence which bodger had plated over. It’s a double skinned affair and the plate fitted to the rear was poorly welded. I put a screwdriver under it and levered it off, it didn’t put up much of a fight. I then drilled out the spot welds to get the outer valence off. It also had a bit of a curve to it which i couldn’t see because of the plate. I made a new piece and put it through the stretcher to get the curve.
Next i moved onto the rotten chassis leg, this was chopped out and a new piece made, i made this from 1.5mm steel which is hard going to shape and bend with a hammer and vice. I made a schoolboy error by attaching one side of the chassis leg which meant I couldn’t get access to weld the eye for the spring hanger. There is enough on the outside to allow welding so all is not lost.
I keep forgetting to take more pictures as I go along. The chassis leg is really strong now so onto the other side.
Well as you can see the other side is much worse than the first, it is rotten with patches all over the place. The wheel tub is welded to it so i have started cutting it away to see the extent of the rust. The wheel tub has been plated and then plated over that. I am going to chop the whole thing out and fabricate a new one. It won’t be the same shape as I don’t have an English wheel. It will be made to fit as well as i can manage.
I welded a brace across the chassis leg where the wheel tub is so that hopefully nothing moves. This is really soul destroying sometimes working on your own with no one to bounce ideas off. Tomorrow is another day so hopefully will make some progress. Please feel free to comment good or bad. All the best for now, Norman
Hi Glen, You could be correct there, my neighbour asked if i was building a car. I said no i was trying to restore one, i sometimes think i should have put a wheel in each corner of the garage and built something in between them. Hey ho the joys of old British cars. Norman
I feel your pain, when I was fixing the van I sort of had an idea what I was doing, but in other times a mate would have popped round and had a look and a brew and set me on a better track. But because that couldn’t happen I ended up soldiering on and either getting to the right place or doing it again later (you are a step ahead though... you haven’t had to fix your own work )
Great work, and Tom gave me a funny look as I made a face reading about the eye incident. I read it to him and he made a very similar face too
Yes two heads are always better than one. The eye incident still nips and when it scabs over it feels like there is a big lump in my eye. The temptation is to pick at it but that starts the process over again. I will try to get my mind in a better place tomorrow and hopefully make better progress. I do a lot of standing looking at something first then grab the grinder and hack it out. It is coming along but not as quickly as I would like. Norman
Today i made a big hole, it’s not easy to see from the picture but i chopped the wheel well out. It took a while as i was cutting through four layers of metal at some points. I was getting through cutting discs at an alarming rate and thought I would run out. One of my neighbours came over with a pile of grinding and some cutting discs. This is the second time he has done this, he was cleaning out his shed. I must get his grand kids something.
Next i started cutting away the rust on the rear chassis leg, not much rust here just a few pin holes ha ha. I chopped the side off the deep part of the chassis leg and set about cleaning up the metal. The bump stop for the axle fits here so i will need to reinstate that part with captured nuts tomorrow. I treated the area with hydrate 80. I have a lot more chopping to do but i will get to that tomorrow.
I will also need to look at getting something that resembles wheel arches. I have a repair panel for ONE side but can’t get one for the other. I was hoping to get to some autojumbles this year armed with a cardboard template of the arch and see if i can get anything close but that doesn’t look likely. I don’t have the skill to fabricate one from scratch and it also has a little step from the curve that runs to the rear corner. If i got a pair of something close to the profile i will just loose the step. I don’t really know where to start looking for arches, any suggestions welcomed. That’s today’s exciting instalment more tomorrow. Please feel free to comment or offer any advice etc. Stay safe, Norman
Thats one very rusty car, great progress. You could try making a wheelarch repair, look at a few you tube videos, cut some plywood shapes to form steel over/around, you'll learn the skills by having a go!
Failing that, as it is an ‘unseen’ part could you not make them in several parts using a drum or something with a similar diameter? From what you have shown in the thread you have developed the skills.
If it doesn’t turn out right you can try something else and if it does you have a new skill for the next one.
Yes there is no doubt in the real world this would have been scrapped years ago. We all know as far as cars are concerned we don’t live in the real world. I have seen many cars brought back to life that you wouldn’t think was even possible. The suggestion for the Holbay unit is good but lots more money. The car actually gets along ok with the standard engine.
Thanks for the encouragement and suggestions, i will see what’s possible With the wheel tubs and arches as i go along. Cheers, Norman