1978 Reliant kitten rebodied in hand formed aluminium

R Tech are great welders, should make your life a lot easier.

I advertised my old TIG welder which I have had since the 90s because I'm not prepared to spend any money on it to have the foot pedal repaired. To my amazement, it sold the very next day closely followed by the plasma cutter, the proceeds of which are a considerable help to fund the new R-Tech unit.

In parallel with the bodywork, I've been working on the braking system. It was always the plan to use the standard Kitten handbrake cables for reasons of availability and price. I try to avoid anything custom made where possible because it makes sourcing spares so much easier. As it turned out, the outers were 80mm short but it was an easy fix to fab up an rearward extending bracket to house the adjusters and make the car suit the cable. For the hydraulics, I've opted for kunifer pipe rather than braided stainless. The rear pipe is partially formed just needing finishing around the new handbrake bracket. 








I have to say at the outset that I'm not a lover of bias pedal boxes but as I didn't want to make one, I had little option because I couldn't find an after market single master cylinder one. But the saving grace is that I managed to find a new OBP unit which was being sold as surplus to requirements and half the retail price. I remember that I had a similar system on the Phoenix and SVA stipulated that it was set to maximum braking on the front and locked in position with a roll pin. I'll probably do the same on this eventually but before that it will be worth having a play with the balance.. 

I keep promising myself to splash out and get a CK torch for a bit more finesse - The Binzel torch on mine is not overly large and heavy but its the cables and sheath that can make it more cumbersome than it should be.

For some unaccountable reason and whatever it was is was it is now coming back to bite me, I fitted the B post profile a few inches rearward of the the actual B post itself and to compound the problem, the quarter panel is short by the same amount. I have absolutely no idea why I did this and why on earth I didn't weld on an extension piece before the quarter panel was inextricably fixed to the body frame is yet another imponderable but for whatever the reasons, we are now where we are which is in some difficulty. As a measure to try to get round the problem I butted the extension piece (that takes the quarter panel to the B post position) to the quarter panel and riveted them both to the aforementioned B post profile with the intention of welding down the joint; nice and easy with steel behind the joint. Unfortunately although both panels were constrained by rivets, the inevitable shrinkage occurred all the way down the extension piece making quite a valley and even I couldn't present it to the painter like that. Fortunately I hadn't welded too far before noticing the problem. So the next step is to remove all the rivets and cut out both the steel sections and then continue welding and hopefully planish it up into a half decent panel.

Not the best of days yesterday but not so good days are inevitable with any project and, in a sense needed, to accentuate the good ones. I had a really off day continuing welding the extension piece to the quarter panel. Welding vertically downhill I was unable to keep the tungsten within the critical distance from the job and ended up with oxidation of the joint which is about the worst situation possible when welding aluminium because once oxide is in the joint, removing it is nigh on impossible and further welding cannot proceed. But I persevered and got to the end with the panel looking as distorted as a Smiths crisp and a weld so bad I'm too embarrassed to show you. I'll revisit it later on but am fully prepared to cut it off and start again. 

I realised right from the outset that I would have trouble welding the body on the frame which is why I sought the help of a professional who sadly declined. But I remembered my tutor from when I learned to gas weld aluminium at Exeter college who retired a few years ago but I know he still takes on welding jobs locally. I gave him a call and he said he would help and try to get over next week. If that happens it will be a huge relief.

Welding downhill is going to be a struggle for anyone so don't beat yourself up about if.
Perhaps try up hill even if you can only do say 15mm a time .
Perhaps use an airline to cool between welds and/or a wet rag.

Even if your old tutor can just give you some tips and pointers on possible ease of attack I'm sure it will help a lot with confidence.

You're doing a lot better than I think I ever would!

Well done John. You're the man.