Cut out the rot on the inside of the B pillar. Most of the rot is isolated to the bulkhead so I shouldn’t have to make too many repair sections (thankfully).
Made the first of a few repair panels I’ll need:
Trimmed down the O/S closing panel and spent a fair while getting the fit right. I joggled the edge on the new panel which gets tucked under the old panel. The panel has the returns like the original either end so I’ll be able to replicate the spot welds joining it to the B pillar.
A bit of a change from all the chassis work I’ve been doing (it’s not finished yet, but I want to get the O/S bits sorted before I turn my attention to the N/S floor and the delights that the sliding door track and middle sill will offer).
Started grinding the paint off the O/S panel. Found an impressive amount of filler, however the metal underneath is solid.
Drew a straight-line across the panel and committed the cut (I didn’t have to cut quite as high as I originally thought which will save some effort). I’ll come back to this panel once I’ve sorted the B and C pillars.
B pillar condition wasn’t too bad, however the front arches are knackered (which I already knew):
Checked the fit of the B pillar repair against the new arch (it fits better than this picture suggests; the clamps fell off):
And cut the B pillar repair down to size. It still needs a bit of fiddling to get a perfect fit. I’ll then use this to aid me in fabricating the inner bits of the B pillar repair.
Zinc primed all of the chassis bits I’ve been working on. Epoxy on tomorrow then first floor pan in at the weekend! A long night made easier by fresh pizza at home from Max.
Some more chassis fun from over the last few weeks.
I decided to finish off the chassis work before the floor goes in and I’m glad I did. Annoyingly I had to remove the brake cable guide tube I’d welded in as access would’ve been awkward (it only takes a little while to unpick it anyway). So chop chop. You can see the rear of the repair I had to make to the other side, and the welds for the cone section.
I fabbed the easiest bit first.
I then realised the piece I’d made wasn’t following the curve of the chassis rail properly so ended up making this repair piece (made from a few separate pieces for simplicity):
There’s some nice looking welds on it too!
And trail fitted, looking a bit neater.
While the paint dried on this side, I started looking at the N/S chassis rail which also needs some work, but is no-where near as bad as the O/S.
I’ve managed to retain most of the cone section on this side (I replaced it entirely on the side I’ve just done). Left overnight in rust treatment.
I then epoxy’d the inside of the O/S:
And began fabricating the repairs for the N/S. I managed to get away with just two simple sections on this side. A piece here:
With flanges bent into it, and a cover piece to go on top of it.
Everything then got a coat of paint on the inside surface:
And all welded in:
The chassis section around the rear torsion beam is now solid again. I need to weld a small cone section on the N/S, I’ve made the piece so just need to fit it. Bring on the floor!
Todays efforts. Welded in the cone section that strengthens the rear torsion bar. It was a bit of pig getting the welding torch in position for some of it and the welds could’ve been a little neater but the penetration is good. I’ve drilled a hole in it so I can cavity wax it and fit a bung later. I’ll be glad not to have to do this section again!
Welded a small patch on the only floor support I didn’t end up replacing:
Redid the welds joining the front top hat to the floor (these were some of the first welds I did and penetration wasn’t great on them).
I’ve welded on two new tabs for securing the wiring loom to the chassis:
Given the floor another coat of zinc primer and a first coat of epoxy mastic. The mastic went on much better this time; I think last time I didn’t thin sufficiently and had the inlet pressure too low. Starting to look shiny:
I also cured the paint on the stove build. My mate now has this, and I think he liked it. I need one now!
