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So i have another one that needs some work. Although its not for me. A friend had dropped this off with me as it needs some love.  Its a Rev1 Japanese import and has been off the road for the past 10 years.  So the good bits Its a T-bar Nice low mileage confirmed at 70k miles Has the following extras Power steering Folding Mirrors Aircon MOMO steering wheel Mudflaps Yellow steering fog lights The bad bits Automatic Gearbox Early brakes and suspension Cloth interior with a small tear in the drivers seat The paint is very bad. Boot is full of water Smashed window The Ugly Rust Bodywork/paint needs alot of work Previous crash damage and has had repairs but not done very well. Both front anti roll bar mounts are cracked. Here is some pictures of the offending areas Drivers sill  Passengers sill and door  Front boot floor  Anti roll bar mounts  In general the rest is rather tidy.    The rear arches need no work at all and are still shockingly clean. The sections behind the rear bumper are solid too just would benefit from a clean up  Continuing the inspection i pulled the front bumper off to have a look at some suspect things  And found the front end has been crashed and half straightened too  Washers shimming up the headlight  That will take a bit of work but not unachievable. The plan is to pull the rest of the front apart and do similar to mine replacing the outer skin of that bent chassis leg. The rest of the bodywork should straighten with a bit of pulling and hammer work. Ignoring that mess I made a start on the sills instead |
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ToolsnTrack
Posted a lot
Homebrew Raconteur
Posts: 4,128
Club RR Member Number: 134
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Jan 18, 2023 12:25:33 GMT
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Holy hell, thats a project.
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Jan 18, 2023 13:05:11 GMT
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Holy hell, thats a project. Its going to be less work than my own mk2 so by that standard its not too bad  |
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Jan 18, 2023 16:55:32 GMT
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With a bit of poking i decided that the only way to get it right is to take the full length sill off. It was thinned due to rust most of the way down so off it comes.  Ill neaten up the cut later when i make the new sills. Lots more cutting. Ensuring as much as possible to keep the bits you remove in decent shape. That way you have a pattern to copy. Looking towards the back there is plenty of rust to deal with in the inner structure.  All the way back to the main channel and strengthening plate. It wasnt looking great so out it comes too  This is where I'll start making new pieces.  Of course the inner sill got a good scrubbing with various wire wheels and anywhere I'm not welding is treated with Hydrate 80. Everywhere is sprayed with zinc weld through primer. Add primer between the panels and weld them together before lining them up in the car..  Welded in from underneath using the original spot weld holes that i drilled out. Onto the next piece in line which is this  Again a template and a bit of hammer work quickly takes me to a panel.  Sprayed with primer  And welded in place.  Same with this next piece, template, hammer and paint  That goes in here, its a bit messy since i had a bit of trouble with the welder. Apparently its going to need some attention again.  And there we go, it cleaned up ok.  There is still 2 more inner sections to do before i can do the outer skin and then the bit of inner arch where it meets the sill needs making. |
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ToolsnTrack
Posted a lot
Homebrew Raconteur
Posts: 4,128
Club RR Member Number: 134
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Jan 18, 2023 17:09:02 GMT
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Good grief, no messing on the pattern replacements!
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Jan 18, 2023 19:07:14 GMT
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Good grief, no messing on the pattern replacements! haha, might aswell make something the matches the original one. it takes a little longer but its much more rewarding and i know everything will it because i have matched the original |
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Jan 23, 2023 19:12:28 GMT
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Great fab work, come and make some bits for my Nissan van!  |
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75 Range Rover 2 door 82 Range Rover 4 door
84 Range Rover 4 door 78 Datsun 120Y 2 door
78 Datsun 620 Pickup 81 Datsun Urvan E23 86 Datsun Vanette van
98 Electric Citroen Berlingo 00 Electric Peugeot Partner 02 Electric Citroen Berlingo
04 Berlingo Multispace petrol 07 Land Rover 130 15 Nissan E-NV200 15 Fiat Ducato
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Jan 23, 2023 23:30:50 GMT
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Great fab work, come and make some bits for my Nissan van! thanks, think i already have enough of a handfull here  |
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Getting the shape right on this next piece is a bit critical as it needs to be plug welded to the outer sill so it has to be just about touching where the outer sill will be. Obviously the outer sill has to be the right shape for that to work aswell. The previous owner had already purchased a pair of sills for doing this job and you could be forgiven for thinking they would be the correct shape. Using a pin gauge i compared the profile to an undamaged section on the originals.  Yea its a mile off. Not a total waste of time though i'll use it for the steel and reshape it so that it fits. Thats a side project for later lets get the inner pieces finished first Flat template  In it goes  And the next one   Welded in  Now i can do something about the outer sill In typical fashion i decided to make a tool with a few things i had laying around the place. Starting off i had a piece of c channel which came off the new wagon box.  A couple of bits of box section and old arms off my mr2..  Welded together with some heavy wall tube.  And then a couple of bits of wood fit inside the c-section with a chamfer on one corner, the sill panel sits in there and with some jumping up and down on the handles is enough to add some extra curve where its needed.  I think there is improvements to be made but its a promising idea for getting a consistent curve down a long piece. It currently works clamped to the bench but i think in future some feet might be in order. Possibly a parallel linkage to make sure it moves vertically. Much closer to fitting now.  Some more adjustments and the profile now matches.l  I finished the clean up then applied some hydrate 80 and sprayed all the exposed bits inside the sill.  Then trimmed the new panel, drilled all the spot weld holes and sprayed the panel  In it goes  And of course all the plug welds are done aswell. Need to be careful not to forget that the inner strengthener is supposed to be welded to the outer sill.  Some grinding on the welds and a quick squirt of paint later.  3 more pieces still to make for this sill section before its finished which i will get to. |
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jimi
Club Retro Rides Member
Posts: 2,224 
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That's a major improvement over mr2B's dismal efforts 👍
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Black is not a colour ! .... Its the absence of colour
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Its not been all out on the jag, i have been cracking on here so i started on the next piece which is at the back of the sill behind the side vent.  Its not an overly complex piece so i made and welded in on an evening  The only critical piece of this one is making sure the side vent sits correct with the sill so test fitted everything a few times before welding it in.  Next up is the sill end cap.  It was an easy bit. I took a profile off the other side.  With those bits i can now make the inner arch to lower sill section  This took quite a bit more work, And in the end i had to cut the piece in half and finish shaping them separately.  First Piece in  And then the lower part took quite a bit more tweaking.  Welded in, its a bit of a milestone as that is one side done.  Oh actually not yet, i found some more rust. On the inner arch to boot cavity.  |
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jimi
Club Retro Rides Member
Posts: 2,224
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Great work 👏👍 Mr T would be happy with that 😎
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Black is not a colour ! .... Its the absence of colour
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Apr 26, 2023 10:29:08 GMT
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Really amazing fabrication. Be good if you could show a little bit of how you make a repair panel so we can see how you do it. Great stuff.
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Apr 26, 2023 15:30:44 GMT
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Great work 👏👍 Mr T would be happy with that 😎 I think he would "pity the fool" who decided to take on the job. |
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Apr 26, 2023 15:32:30 GMT
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Really amazing fabrication. Be good if you could show a little bit of how you make a repair panel so we can see how you do it. Great stuff. Ill do my best to take more photos of the next piece as its a bit of a good one. Tbh most of the time i just make a template, cut out the steel then hit it with various hammers till it looks how i want.  |
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