teaboy
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Make tea, not war.
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Jun 13, 2024 20:16:56 GMT
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You have the patience of a saint, Mr T Cheers, Phil. You live in the country with the best contemporary music of allsorts, but go to a concerts of some german copycats??? ;-) The thread is full of German cars, it seems like the right thing to have some German Rock music to go with it. I enjoyed an Australian band (together with one of my 13 year old daughters) in the Amsterdam Arena. But we loved the concert! Thom ps: they did not serve cake of any sort :-( I'll bet that was a good show. Yesterday's exciting discovery... ![](https://i.postimg.cc/Dw380YH6/IMG-6672.jpg) Was that there might be some rust on this car. I couldn't ignore it, I started cutting it out. ![](https://i.postimg.cc/YCvtv9Kc/IMG-6676.jpg) When I lifted it away, it was a bit scabby in there. ![](https://i.postimg.cc/K8CxB2x1/IMG-6677.jpg) It doesn't look too bad, what is the piece of chassis like? ![](https://i.postimg.cc/cJYZcbLX/IMG-6678.jpg) It is a good job that I'm replacing that bit. I gave the area of floor a good clean up. ![](https://i.postimg.cc/DZThpPWF/IMG-6679.jpg) I think I will just treat the floor, it doesn't need replacing. That hole that is in the picture above is from the spot weld drill. I used some of that phos clean stuff on it, you can see where it has gone black straight away in the pitted area. ![](https://i.postimg.cc/PxQjgvZD/IMG-6680.jpg) That was shiny when I cleaned it up with no sign of any rust remaining but it must have been hiding in those pits. I didn't bother making the replacement piece for the chassis because it had started raining whilst I was in the tent and I didn't fancy walking up to the shed and getting soaked, might make it next time. Cheers
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teaboy
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Make tea, not war.
Posts: 1,982
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Jun 13, 2024 13:05:47 GMT
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Do they still have that schoolboy playing guitar? ![:D](//storage.proboards.com/forum/images/smiley/grin.png)
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teaboy
Posted a lot
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Make tea, not war.
Posts: 1,982
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Jun 12, 2024 20:58:04 GMT
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Yes, I am still alive and kicking. I've been away for a few days, 'darn sarf'. The Doc was landing at Heathrow last Friday, now that her secret mission is completed so I met her in Wembley. I had booked B&B which offered free on street parking but apparently that doesn't include days when there are events at the stadium. I had managed to coincide with both football and rugby matches on consecutive days so it cost me sixty quid in parking permits. As I found myself in London on a Saturday morning it meant that I was a long way from Ten Acres Cafe but the Doc found this place, which was half decent and didn't have a menu consisting only of variations on smashed avocado. ![](https://i.postimg.cc/jd44sNkD/IMG-6656.jpg) By lucky coincidence, there was a band playing at the arena in Wembley on Saturday night. ![](https://i.postimg.cc/hjmGKLs6/IMG-6666.jpg) It was cheaper to see them in France last year than it was to see them in London. Sunday we called in to see my daughter, granddaughter, son-in-law and the very soon to be launched massive bulge that will be my grandson. Anyway, there has been nothing exciting happening in the tent. The job at hand is cleaning the driver's side floor to prep for paint. I did the large areas with the wire wheely thing on the grinder but now I'm into all the fiddly bits where you can't get the grinder in. I tried a drill with a wire brush in it but it was too difficult to use. I ended up with these tiny brushes. ![](https://i.postimg.cc/FKtg9ZVX/IMG-6673.jpg) In the Dremel with a flexible shaft thing. ![](https://i.postimg.cc/T3jhDJX6/IMG-6671.jpg) Where I am working, in the picture above, there is the chassis rail on the left and the outer floor on the right drops down to the same depth as the chassis. This leaves a trough the length of the floor where you can't get the grinder in to remove the underbody coating. As you might imagine, cleaning all that off with a Dremel has taken ages and it doesn't leave any photogenic results. One part that is definitely not photogenic is this flange on the chassis rail. ![](https://i.postimg.cc/Dw380YH6/IMG-6672.jpg) It is quite pitted with rust and I am concerned as to what might be going on in the seam with the floor. It is going to have to come out and be replaced. Cheers.
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Last Edit: Jun 12, 2024 21:01:57 GMT by teaboy
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teaboy
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Make tea, not war.
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Yesterday I thought that it would be an excellent idea to start cleaning up the floorpan ready for paint. It is still a good idea but I remembered an order of procedure problem. A long time ago, I removed the seat crossmember so that I could repair the floor beneath it. This will need to go back in before the floor is painted or it will burn it back off. I had cleaned and epoxied inside the crossmember when I took it off but I needed to sand the paint off the flanges where it will be welded. ![](https://i.postimg.cc/25HYWJqW/IMG-6641.jpg) I also sanded the floor where it fits. ![](https://i.postimg.cc/x13nfqnt/IMG-6642.jpg) I didn't fancy loads of masking up to spray weld through primer on there so I mixed up some 2k weld through and brushed it on. ![](https://i.postimg.cc/DZ8TPgsM/IMG-6643.jpg) The floor too, of course. ![](https://i.postimg.cc/cJ1ZrZJZ/IMG-6644.jpg) In order to have a fighting chance of getting the seat back in, the crossmember needs to fit in exactly the right place. This is where the seat crossmember jig thing comes in. ![](https://i.postimg.cc/Px9k3wQr/IMG-6645.jpg) As I don't have any really massive welding clamps to hold the crossmember to the floor, I used a few tek-screws to hold it down for welding. It seemed to work ok so I welded it in and ground the welds back. ![](https://i.postimg.cc/h4QnJ2KJ/IMG-6647.jpg) I even remembered to put the main battery cable in before I welded it down. That is now fixed in and not coming back out in a rush, just need a drop of spooge to protect it before it gets painted. ![](https://i.postimg.cc/Y0FBJCdN/IMG-6648.jpg) I am still ignoring the inner arches... Cheers.
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teaboy
Posted a lot
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Make tea, not war.
Posts: 1,982
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I started my last report saying that I was feeling under the weather and that hasn't changed. I got absolutely nothing done at the weekend, just didn't have the energy. I had good intentions on Monday after work but it didn't happen. It could, quite easily have been the same story tonight but I forced myself to do something. It had to be something straightforward and easy so I looked at this bubbly bit around the jack point. ![](https://i.postimg.cc/6pkZq9n0/IMG-6447.jpg) I removed the jacking block. ![](https://i.postimg.cc/VkSCx0bb/IMG-6634.jpg) When I wire wheeled it it looked like this. ![](https://i.postimg.cc/Jn8HHTYb/IMG-6635.jpg) There was a little bit of rust on there but I think it will respond ok to some chemical treatment, I don't feel the need to cut it out and replace it. As I had the wire wheely thing out I decided to start cleaning up the rest of the driver's side floor. ![](https://i.postimg.cc/zfKRBm7z/IMG-6637.jpg) I have to remove all the undercoating because whilst it is in place we have what is effectively, a Schrodinger's floor. It may be rusty and dead, it may be shiny and alive or both things at once, but we will never know until it is observed. To observe it involves numb fingers and getting covered in this stuff. ![](https://i.postimg.cc/sgthsfpH/IMG-6636.jpg) There are a couple of areas that will need some rust treatment of some sort after I have finished cleaning up. ![](https://i.postimg.cc/vBvgrWCC/IMG-6638.jpg) Maybe I will feel a bit more energised tomorrow. Cheers.
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teaboy
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Make tea, not war.
Posts: 1,982
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May 31, 2024 21:03:01 GMT
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I'm still feeling a bit under the weather today. The sun came out this afternoon so if I'm going to be under the weather it might as well be under the sun. I'm not the fastest of workers even when I'm feeling tip-top so I'm really slow at the moment. I managed to drag myself into the tent to do a bit more welding. Now that my parts are painted... ![](https://i.postimg.cc/rmFLQwdr/IMG-6616.jpg) I unmasked it, sprayed on some weld through primer then welded the chassis back in. ![](https://i.postimg.cc/FKXgQKV3/IMG-6625.jpg) I had a cup of tea then went to smooth it all down. ![](https://i.postimg.cc/qv3XYKyp/IMG-6626.jpg) I was reasonably pleased with that so I cleaned off the back end of that chassis rail and treated the whole lot to some spooge. ![](https://i.postimg.cc/xT73t5ks/IMG-6627.jpg) At my current speed, that little job took me two hours. In other news, my car came with an armrest. I'm not a fan of armrests in cars because when I'm driving I am usually holding the steering wheel or changing gear. This brings us to the second problem with armrests, it is in the way when you are changing gear so I always had mine in the lifted position. What this all means is that I don't need an armrest so I got one of these. ![](https://i.postimg.cc/SKLLQpg5/IMG-6624.jpg) It is a short, armrest delete console. I shall look forward to the time when I can fit that. Cheers.
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teaboy
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Make tea, not war.
Posts: 1,982
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May 30, 2024 19:06:35 GMT
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I think you need to stop looking for holes or prodding brown stains with your finger I can't help myself, Bstardo, I'm mad for it! ![:D](//storage.proboards.com/forum/images/smiley/grin.png) It was quiz night yesterday, we were third. Two team members missing, our sports expert who seems to be making a habit of not showing up and the Lovely Doctor who has gone on a secret mission to Madagascar. I did have a quick look in the tent before the quiz, had a bit of a clean up on the new piece of floor then treated it to a drop of spooge. ![](https://i.postimg.cc/0Q7k1z9H/IMG-6607.jpg) I woke up this morning feeling a bit pony, I think I'm coming down with the man-flu which isn't ideal. I was feeling tired and aching when I got home but there is no point moping around feeling sorry for myself so I went out to the tent. Looking at the new piece of floor from the inside. ![](https://i.postimg.cc/R0VPDb2H/IMG-6606.jpg) The eagle eyed amongst you might notice a slit in the floor at lower left of the picture. This is a leftover from when I replaced a different piece of floor ages ago. I had only welded three sides of the repair for some reason and left the forward edge so now was as good a time as any to finish it off. ![](https://i.postimg.cc/CLWSS023/IMG-6610.jpg) With that taken care of, there were a couple of plug welds to do where the front seat crossmember sits on top of the latest new piece of floor. I spot weld drilled them. ![](https://i.postimg.cc/fRmZbFnJ/IMG-6611.jpg) Plugged them up. ![](https://i.postimg.cc/1zKQGqzS/IMG-6613.jpg) Then filed them off. ![](https://i.postimg.cc/brZffV9Y/IMG-6614.jpg) Now I just need to put the piece of chassis back in over the floor repair, but I decided to get some epoxy on as much of it as I can beforehand. ![](https://i.postimg.cc/4dLRMRtF/IMG-6615.jpg) Of course, I did the piece of floor too. ![](https://i.postimg.cc/rmFLQwdr/IMG-6616.jpg) The bits of masking tape are to keep the epoxy off the areas where I need to weld, they will get weld through primer. That was enough for me tonight, I'm going to see what medication I can have. Cheers.
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teaboy
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Make tea, not war.
Posts: 1,982
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May 28, 2024 20:41:01 GMT
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It was a bank holiday weekend, yay! It was the Lovely Doctor's Birthday the other week and as this was the nearest weekend to it that she was free, so we went away to celebrate it. We stayed in York so that we could also spend time with our youngest daughter. This is the Doc training to be an axe killer. ![](https://i.postimg.cc/Y2gxbHjP/IMG-6599.png) On the bank holiday Monday we went up to Filey for a walk on the beach. I did find a tea bar so all was well with the world. ![](https://i.postimg.cc/TYJJvJVq/IMG-6602.jpg) All this means that the floor that I tacked in on Friday. ![](https://i.postimg.cc/50hxnqjt/IMG-6595.jpg) Was still only tacked in when I got home from work today. It did look like it was going to stay like that for a bit longer because when I got home it was pouring down. I sat in the kitchen drinking tea for some time and complained that it was a conspiracy, but it did eventually stop and the sun even came out, so I quickly dragged the welding gear down to the tent before it changed its mind. I welded it in from below, which is not much fun with all the sparks dropping on you. ![](https://i.postimg.cc/28hXbW4V/IMG-6603.jpg) ![](https://i.postimg.cc/c1VbLhtp/IMG-6604.jpg) That went reasonably well, considering, so I gave it a quick tickle up with the power file. ![](https://i.postimg.cc/qvrD87LQ/IMG-6605.jpg) I don't need to file it all off because the chassis piece will cover the rest of it. I also gave the inside a quick going over. ![](https://i.postimg.cc/R0VPDb2H/IMG-6606.jpg) I decided that I didn't need to go too mad with that either because it will be painted, covered with sound deadening, painted again then covered with carpet, so who is going to see it? I might put some epoxy on the inside bit of the chassis before I weld it back on, I haven't decided yet. Cheers.
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teaboy
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Make tea, not war.
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May 26, 2024 15:29:44 GMT
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You’ve cornered the market on pipe cutters now, Phil. ![:D](//storage.proboards.com/forum/images/smiley/grin.png)
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teaboy
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Make tea, not war.
Posts: 1,982
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May 25, 2024 22:28:42 GMT
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Nicely rounded off brackets are much better.
I say black uprights.
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teaboy
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Make tea, not war.
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May 24, 2024 21:21:42 GMT
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That looks great.
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teaboy
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Make tea, not war.
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May 24, 2024 21:04:28 GMT
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Limited progress tonight I'm afraid. I have my bits prepared and primed. ![](https://i.postimg.cc/MKFxsZph/IMG-6588.jpg) When I made the new piece of floor I used the outside face of the old floor as the test template. ![](https://i.postimg.cc/4yNjcfpP/IMG-6539.jpg) This meant that when it was somewhere near I could offer the oversized panel on top of the hole to check the shape. ![](https://i.postimg.cc/xT4mP3j8/IMG-6547.jpg) There is a slight downside to this method and that is that the flanged over edge is in the wrong place by roughly the thickness of the metal. Ordinarily, this wouldn't be a problem because you would trim the other edge of the panel and move the whole thing over until the flange was in position. In this instance, I couldn't do that because of the fingery dimply bits. There is half a dimply bit at each end of the new piece which has to mate up to the corresponding half that remained in the floor and it is these which dictate where the panel fits, not the flange. When I started to cut the piece in I marked a line where the curved flange should, well, curve. Then it was a case of taking it to the shed to work on it. I did it over a T dolly with a dead blow hammer. The dead blow was kinder to the metal and didn't ruin all the detail of the dimply fingers. It also has a much larger head than a metal hammer so it spreads the load and moves a bigger area of metal. It took a fair bit of faffing about and walking to and from the shed but I think it is ok now. In fact, I was that convinced that it was ok that I started to tack it into place. ![](https://i.postimg.cc/50hxnqjt/IMG-6595.jpg) In the bottom right hand side of the picture you can see an intergrip which I used to ensure that the joint was flat. I didn't get beyond that because the lovely Doctor decided that it was time for me to pack up and go to fetch her a pizza. Cheers.
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teaboy
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Make tea, not war.
Posts: 1,982
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May 24, 2024 16:16:53 GMT
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Great car and fantastic work you've done.
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teaboy
Posted a lot
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Make tea, not war.
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May 23, 2024 20:04:19 GMT
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Nice job on not sharing the biscuits with the person who brought them round so you get more and extra points on blaming the Mrs. That takes skills ![:D](//storage.proboards.com/forum/images/smiley/grin.png) Work on car is ok too I guess. James You've rumbled me, James... ![:D](//storage.proboards.com/forum/images/smiley/grin.png) Long day today, twelve hour shift and, consequently, late home and tired so I wanted a quick and easy job tonight. Now that I have the chassis section repaired. ![](https://i.postimg.cc/Ls0PmBVJ/IMG-6578.jpg) I could give it, and the piece of floor, a quick clean up and some primer. In the picture above you can see the two little holes that I replaced and there is one larger hole which I didn't. The large hole had some corrosion around it which I had sanded off and treated with phosclean stuff from rustbuster which is supposed to kill the rust and phosphate the metal so it is ready to paint. It isn't a very good picture but you can just see the pitting around the hole here. ![](https://i.postimg.cc/0Q0PZpzf/IMG-6582.jpg) The other side was pitted too and when I started sanding it to prep for primer there was rust coloured dust coming from that area. ![](https://i.postimg.cc/Y02kPhgw/IMG-6581.jpg) I'm pretty sure that hole doesn't do anything so... ![](https://i.postimg.cc/BZNJKB9Z/IMG-6584.jpg) ![](https://i.postimg.cc/2yHmNrFL/IMG-6586.jpg) That gets rid of the rust and the rust inducing hole. A quick tidy up and here we are. ![](https://i.postimg.cc/ZKR4Fv48/IMG-6587.jpg) Oh, the original plan was to get some primer on there, wasn't it? ![](https://i.postimg.cc/MKFxsZph/IMG-6588.jpg) I wasn't planning on priming my workmate bench, that was just an added bonus. Right, I'm off for a bacon sandwich and a cup of tea. Cheers.
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Last Edit: May 23, 2024 20:06:53 GMT by teaboy
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teaboy
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May 23, 2024 19:30:58 GMT
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My bench currently looks a bit like the before picture... ![:D](//storage.proboards.com/forum/images/smiley/grin.png)
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teaboy
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Make tea, not war.
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May 23, 2024 13:28:13 GMT
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Good progress there.
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teaboy
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May 22, 2024 20:42:49 GMT
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Fantastic!
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teaboy
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May 22, 2024 18:54:40 GMT
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In fact, we were so busy gassing that we forgot to eat the biscuits. Cheers. I frankly find that very hard to believe....... What can I say? Maybe I have senile dimensions... ![:D](//storage.proboards.com/forum/images/smiley/grin.png) While I am serveral years behind on this thread. Ill chip in here and say thank for the brew! Nice to meet someone who suffers with the same afliction. I will attest to biscuit forgetfulness. But I'm sure there will be other chances to eat some! Amazing work on the Beeeemer. The biscuits have almost gone, I think the mice might have been at them, or possibly the Lovely Doctor... I'm going to have one before it's too late. It has been a horrible day, constant rain and it was still raining when I got home. I was feeling done in and was very tempted to give it a miss but I thought that I might just replace my old holes with the new holes. This is one of the new holes. ![](https://i.postimg.cc/tJvYZ63V/IMG-6562.jpg) I marked the centre of the old hole and also marked the new one, so I could get it in the right place. I cut the old one out and clamped the new one in, lining up my markers. ![](https://i.postimg.cc/SQY6N53k/IMG-6571.jpg) It got welded in. ![](https://i.postimg.cc/Yqc14RBg/IMG-6572.jpg) Then I went to do the second hole and I made a total pig's breakfast of cutting it in which left me with a massive gap to fill. ![](https://i.postimg.cc/Prm11Dd7/IMG-6573.jpg) I tacked it in place, lining up the markers again. ![](https://i.postimg.cc/SxkCdKsx/IMG-6575.jpg) I started welding it a bit at a time, luckily, the thicker chassis is a bit more forgiving than the paper thin floor. ![](https://i.postimg.cc/NjDTzw97/IMG-6576.jpg) I eventually managed to fill it all in. ![](https://i.postimg.cc/wBBJKbDK/IMG-6577.jpg) I gave it a quick clean off, it doesn't look too bad. It is only a chassis rail and not the middle of the bonnet so I think it will do. ![](https://i.postimg.cc/Ls0PmBVJ/IMG-6578.jpg) I wasn't tempted to do any more after totally making a meal of that. I'm going to have a biscuit. Cheers.
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teaboy
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Make tea, not war.
Posts: 1,982
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May 22, 2024 11:01:50 GMT
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What’s going on with the roof?
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teaboy
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Make tea, not war.
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May 21, 2024 20:30:31 GMT
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I don't think it is bravery, more like me desperately trying to avoid making an oil tank Don't be hard on yourself. Hey - it's still all very entertaining and we can all just look forward to the day this car is finished and you get back to the porsche ![;)](//storage.proboards.com/forum/images/smiley/wink.png) by then you'll be a world master at manipulation of tank steel. Is there an oil tank, for a Porsche? I had forgotten all about that. ![:D](//storage.proboards.com/forum/images/smiley/grin.png) Tonight, I went and retrieved these bits which were stuck to the car with magnets. ![](https://i.postimg.cc/JzHkYHtq/IMG-6548.jpg) They needed a slight bit of manipulation to make them play together as there was a bit of a gap instead of a flush joint. They now go together like peas and carrots. ![](https://i.postimg.cc/mgzF9m6Z/IMG-6556.jpg) When I removed the chassis piece it had a couple of massive self tappers in it, I can't remember what they were for but probably the exhaust heat shield. Anyway, they were not the proper screws, they were bigger in diameter so now the two holes were too big to fit the proper screws. ![](https://i.postimg.cc/vm5gqcsp/IMG-6557.jpg) I thought that now was as good a time as any to fix that. The holes look like they were slightly recessed so this is what I did. I drilled a 4mm hole then taped a washer on to the piece, with the hole in the middle of it. ![](https://i.postimg.cc/sXcBzq1m/IMG-6559.jpg) A quick root through my drawers produced this ball bearing. ![](https://i.postimg.cc/Kj818fM2/IMG-6561.jpg) With it sitting in the drilled hole and the washer at the other side I gave the bearing a whack with a hammer. It left me with this. ![](https://i.postimg.cc/tJvYZ63V/IMG-6562.jpg) As there were two holes on the chassis piece, I made another plate. ![](https://i.postimg.cc/Jnmy9M7t/IMG-6558.jpg) I had just started cutting out the old part of the chassis piece when I had a visitor in a very lovely 944. ![](https://i.postimg.cc/6p9m5GHh/IMG-6563.jpg) It was yer man broady and he was bearing gifts. ![](https://i.postimg.cc/MTjsr0Tz/IMG-6564.jpg) We retreated to the house to drink tea and have a natter. In fact, we were so busy gassing that we forgot to eat the biscuits. Cheers.
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Last Edit: May 21, 2024 20:40:09 GMT by teaboy
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