Adventures in Welding

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impstress2003
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Adventures in Welding

Post by impstress2003 » Fri Jun 03, 2016 11:22 pm

Some years ago, Nikki bought an Imp Californian - "Archie" - from Tim Morgan. The car was well known at one time and has been round quite a few club members! Unfortunately, by 2004 it had been on the road 37 or so years, and patching it up wasn't going to get it another MOT. In fairness, the car was dead.

Having decided it was already dead, we decided I couldn't possibly kill it by learning to weld and attempting to weld it up. Well. The jury is still out on that!

So.. 11 years ago, I bought a welder, and resolved to learn to weld with it. So with an afternoon of instruction from Nikki's dad, I set about welding the car up...

... I'm still welding it. (I have done up a few other cars in between!)

I guess what (should) follow here will show what you can do with a welder and a bit of determination. I know that the work I did first was poor - I had to expect that - but I will show it here, warts and all... don't be put off! Hopefully the work I do now is a lot better :D

To start - here's the car as it was last on the road. Doesn't look too bad right? Wrong.... :cry:
Attachments
Archie_Scans3_0061.jpg
Archie_Scans3_0060.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Jun 03, 2016 11:26 pm

So. Baby steps at first. I was very worried about the car losing its shape if I cut out too much metal. Not having any experience I started with the floor and decided to find something solid to weld to. I cut out the rot, and made a patch. There's a lot of things I could have done better, but I had to start somewhere. These days I'd just replace the complete floor. But at least it was a start! Back in those days I didn't have a digital camera so these are scans of prints.

Hopefully in this shot you can see that patching it up wasn't going to cut it for another test!
Attachments
Archie_Scans1_0001.jpg
Archie_Scans1_0002.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Jun 03, 2016 11:29 pm

Next I started repairing the inner wheel tub, as I wanted to work back to the floor and with the inner wing being shot I had nothing to weld it to.

Mistakes here abound again, I really should have started with much larger pieces. I was getting consistent burn through on the welds though, so I'm quite pleased with that!
Attachments
Archie_Scans1_0003.jpg
Archie_Scans1_0005.jpg
Archie_Scans1_0006.jpg
impstress2003
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Re: Adventures in Welding

Post by impstress2003 » Fri Jun 03, 2016 11:34 pm

Next I added a bit more inner wing, and made a piece of floor. I beat the ridges into it with a bolster chisel and a hammer on the ground outside the garage (kind of a large free sand bag). Confidence was building a little so the floor piece was a lot bigger than the previous three pieces. This was only the fourth thing I welded, I should have spent a lot more time practising with scraps but that just didn't interest me:
Attachments
Archie_Scans2_0001.jpg
Archie_Scans2_0002.jpg
Archie_Scans2_0003.jpg
Archie_Scans2_0004.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Jun 03, 2016 11:44 pm

With that piece in situ it was time to sort out the seat tray. It was rotten right through from the front to the back. With a screwdriver I was able to detach it from the heater box by just pushing through the rot. Truly ugly! Fortunately, Tim M had some spare floor sections he had cut from another dead Imp! (In those days there were still Imps getting scrapped quite regularly). I welded a bar across the door for strength. With hindsight, this was not enough, and the car moved quite a lot with the floor removed. The sills were contributing nothing - they were covers and were not actually attached to the floor. It was while I was doing this that the passenger side floor dropped completely, having become completely detached from the sill rail and the seat pan had rotted through where it met the heater sill - it dropped about 2 inches below the sill rail height!

What might not be obvious in the pictures is that the floor already had a patch 6" wide running down it, which had also rotted through!

Also, in the last shot, where the seat tray section has been seam welded in, just check the crack running down the rear wing from the B-pillar. This is what happens when cover sills are fitted and not welded to the inner structure behind the wing. Not good.

Finally - the pipe you can see is the heater hose - the sills were full of expanding foam!!! When the hoses failed, new ones had been run inside the car :lol: at least it kept it going. If it hadn't been for these fixes the car would have been scrapped many years ago :!:
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Last edited by impstress2003 on Fri Jun 03, 2016 11:53 pm, edited 1 time in total.
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Re: Adventures in Welding

Post by impstress2003 » Fri Jun 03, 2016 11:52 pm

Next up I did the last part of the driver's side floor that was visible from inside the car. I was a bit daunted by repairing the rear cross member mounts as they looked complex, and I knew they were a mess (more on those later!) so I decided to finish the main part of the floor and move on to fitting the sills to put a bit of strength back into the body as it was visibly moving at this point.

This piece of the floor is not great. I'd like to think I'll do it again before the car goes back on the road. That being said, it's solid, and no one will see it, but I know it's there. In any case, it's not hiding anything, so it's not unsound. Just not pretty!
Attachments
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Re: Adventures in Welding

Post by impstress2003 » Sat Jun 04, 2016 8:45 am

Next I cut off the complete sill assembly and offered up the new sill. The sill I had was a hand made panel. Offering it up it looked like a good fit. I made a big mistake here by assuming that the panel would be the correct shape. It wasn't - but because I trusted that it would have been made correctly I later fitted panels around it when I should have modified the panel to get the correct fit. In practise, the raised section of the panel under the door was too long by about 1cm or so, and the width of the sill from the top sill rail to the edge of the panel under the door was narrower than a factory sill. For this reason, when the drivers door is shut now it overhangs the sill instead of neatly sitting above the sill rail, so this has left me some issues to sort out. These days I only ever buy ex-pressed sills. When you take one of those it's difficult to twist the panel by hand - they are very rigid, but also, they appear to be dimensionally correct. The hand made ones are quite floppy by comparison.

Looking in the third picture below you can see that there wasn't much of the A-post left!!!
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Re: Adventures in Welding

Post by impstress2003 » Sat Jun 04, 2016 8:57 am

Next I wanted to fit a new heater box. The panel under the back seat tray was rotten where it met the floor, so I started by cutting this back and repairing it. I didn't weld it through to the crossmember mount behind at this time, because the crossmember mounts were shot and I knew that I had nothing there to weld to. So I put in the repair section and welded to it much later when I repaired the crossmember mounts.

Being a bit broke at the time I didn't want to buy a heater sill, so I had a very fun evening where myself and Tim M "fabricated" a heater sill. I worked out the dimensions of it (I wrongly assumed it was straight and not tapered, but never mind... more lessons learned :) ) and cut a piece of steel to shape ready to be folded up. Tim popped over and I clamped the steel between two pieces of kitchen work top. Tim then stood on the top piece of worktop and pushed against the roof beam and I folded over the steel by hand. In spite of the weight I was still lifting both the kitchen worktops, the steel, and Tim!! In any case, I got the panel folded up and fitted!
Attachments
Archie_Scans2_0026.jpg
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Archie_Scans3_0001.jpg
Archie_Scans3_0002.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sat Jun 04, 2016 9:36 am

With the heater box in, I had to replace the inner sill. Normally this panel has holes punched in it - these are there so that they could weld down the seat trays at the factory. The holes allowed the spotwelder arms through to allow the seat tray to be fitted after the heater box/inner sill assembly had been fitted. Above the heater sill I made a new closing panel to go between the seat pocket and the top of the sill, as the original had been cut through to allow the new heater hoses to pass. No great shakes, just a little time to make a new repair section. About this time, I started using a lot of zinc based weld through primer, since I figured it would be difficult to get back into this box section later to apply any rust proofing.

In the third picture below you can see that the door will stick out over the sill. It looks sort of ok in this picture but if you look at the line of the wing you can see it is overlapping the door by several mm. Pulling the door into line with the body you can see that the sill sits back by several mm. The top side of the sill is about 8mm narrower than it should have been at the back. At the front, it is a good fit. I think it's possible that whoever made the panel just didn't appreciate that Imp sills are tapered.

Unfortunately I didn't have a piece of steel large enough to make the inner sill in one piece. I had to make it in several sections! :) I also wasted a lot of time carefully protecting and welding around the wiring harness. I've no idea why, they're easy enough to remove and this one is completely shot anyway!

What I found doing the inner sill/heater box was that it would have been a lot easier to assemble these two panels off the car (that's what I've done ever since) as it was impossible to get to the top of the heater box to plug weld through to the inner sill. So instead I drilled the inner sill and plug welded up to the heater box. Not having a rotisserie made this quite difficult, so for good measure (since I was still very new to welding) I seam welded the top of the inner sill to the heater box behind the B-pillar.

I removed the strengthening bar I had added because I thought with the inner sill/heater sill in place, the car would be strong enough. This was the wrong thing to do - both the A- and B- pillars were completely rotten and not attached to the sills, so were contributing almost nothing to the strength of the car :o
Attachments
Archie_Scans3_0003.jpg
Archie_Scans3_0004.jpg
Archie_Scans3_0005.jpg
Archie_Scans3_0006.jpg
Archie_Scans3_0007.jpg
Archie_Scans3_0008.jpg
Archie_Scans3_0009.jpg
Archie_Scans3_0010.jpg
Archie_Scans3_0011.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sat Jun 04, 2016 9:54 am

With the heater sill, inner sill, and floor back in one piece, time to fit the outer sill, and fix the B-pillar!

Factory sills were not spot welded behind the B-post. In practise, the B-post was welded to the outer sill, then the outer sill was fitted up to the assembled floor/inner sill/heater sill/seat tray. So the spot weld arms wouldn't reach behind the b-post.

Hopefully these show clearly how the factory type sills tie into the car behind the outer panels.
Attachments
Archie_Scans3_0012.jpg
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Archie_Scans3_0014.jpg
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Archie_Scans3_0021.jpg
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Re: Adventures in Welding

Post by Dave ' Linwood ' Lane » Sat Jun 04, 2016 10:10 am

major weldathon going on there - looks good :)
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Re: Adventures in Welding

Post by The Nun » Sat Jun 04, 2016 10:58 am

Mega job, but good for giving it a go, always interesting to see how IMPs all rot away in slightly different ways, what remains good on some bad cars is totally rotted out on others, great photos, keep them coming, and Im sure Grahame might like a few for the magazine too with a short write up for all those who cant access the forum? :wink:
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Re: Adventures in Welding

Post by Grahame59 » Sat Jun 04, 2016 11:53 am

The Nun wrote:…and Im sure Grahame might like a few for the magazine too with a short write up for all those who cant access the forum? :wink:
Yep, always glad to receive restoration stories for Impressions. Perhaps wait until it's finished and send some photos of Archie's journey to completion plus some text. The car clearly has an interesting history and maybe Tim might also like to send some background info from when he owned it. Thanks.
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Re: Adventures in Welding

Post by impstress2003 » Sat Jun 04, 2016 4:34 pm

I'm pretty sure Tim has some stories about this car!

With the sill welded up it was time to tackle the A-post. There wasn't much to go on but I got lucky and bought a brand new coupe A-post on ebay for about £15 at the time. Rather than using this panel I used it to make templates. These pictures have been posted before but these are better quality scans. It was interesting to dismantle the post and see how it is put together. Unfortunately it was so rotten that it was easy to move the door up and down. This made lining up the sill/body difficult as the front wing was made of filler for the bottom 10 inches or so and was not attached to either the A-post or the inner wing.
Attachments
Archie_Scans3_0022.jpg
Archie_Scans3_0024.jpg
Archie_Scans3_0025.jpg
Archie_Scans3_0026.jpg
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Archie_Scans3_0031.jpg
Archie_Scans3_0033.jpg
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Re: Adventures in Welding

Post by ImpManiac » Sat Jun 04, 2016 7:54 pm

:shock: What an interesting, enjoyable and inspirational thread, Si! :D Thank you for taking the time to scan the photos and write it up so well. I shall be going through very similar growing pains myself, when the time comes for me to get stuck in to my Chamois. I just have a garage to rebuild first... :?

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Re: Adventures in Welding

Post by chris d » Sat Jun 04, 2016 9:06 pm

good effort
best way to learn is by giving it a go.
keep it going
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Re: Adventures in Welding

Post by impstress2003 » Sun Jun 05, 2016 1:34 am

Thanks Paul, Chris. There's a lot more to come...

Next I moved onto the front inner wing tub. I bought a front wing from Jeff Day which was pressed on his new tooling. The panel was superb, with no wrinkles under the headlight and it was complete with all the standard factory returns, ready to fit. At the time, Jeff was selling some of the pressings which had wrinkles under the headlight very cheaply as repair sections, so I bought a spare outer wheel arch and decided to use this as a repair section for the inner arch. These days I would make the inner repair section myself using the shrinker/stretcher.

Unfortunately the inner wing tub was seriously corroded and the rot went so far into the car that when you sat in the drivers seat, if you looked towards where the front o/s wheel would be, there were holes in it above the level of the bottom hinge box. Again, with hindsight, I could have made a much nicer job of this repair, but it was the first time I ever repaired a wheel tub and also the first time I repaired an inner arch. All good experience though!

As part of this repair I offered up the new wing a lot of times to check for fit. Looking back it wasn't long after I completed this work that I realised that the sill was too long at the front - only by a few mm - but I pushed the wing to fit over it and now the door gap is not right on the driver's door. It will be easy enough to sort when I have the final door fitted, but I should have trusted the pressed part, I've fitted several of Jeff's front wing repair panels and dimensionally they are spot on.

There are a lot of pictures of this part of the car as it took a lot of welding to get right, so they'll be split over a couple of posts.

It was while I was doing this that I burnt my hand quite badly on the top of the front wing. When I had seam welded it onto the edge of the front panel, as soon as I finished the last weld I immediately took off my gauntlets and then (stupidly) leant on the brand new weld to reach over the car and remove a clamp. It took a few months for the burn to fade! These are still scans of pictures. I bought Nikki a digital camera for Christmas soon after this work so hopefully the picture quality will improve!

During this piece of work I also repaired the scuttle. It's essential that if you have scuttle repairs to do, you must do them before you fit any new wings as the scuttle panel is welded to the A-post behind the front wing in front of the door. I also had to repair the boot floor, so I made my own boot floor corner repair section and welded it in!
Attachments
Archie_Scans3_0036.jpg
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Archie_Scans3_0046.jpg
Archie_Scans3_0047.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sun Jun 05, 2016 1:45 am

More pictures of the wing/inner wing repairs.
Attachments
Archie_Scans3_0048.jpg
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Archie_Scans3_0059.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sun Jun 05, 2016 1:49 am

So, these are the last of the scanned pictures. I took a couple of shots to show the state of the o/s/r suspension turret from inside the car - this was truly awful as I will show, and also the state of the passenger side floor. I wish I had had the shell blasted, it would have been a much less messy job, but I honestly think the car would have collapsed. There was just no strength in it at all!
Attachments
Archie_Scans3_0035.jpg
Archie_Scans3_0034.jpg
Archie_Scans3_0032.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sun Jun 05, 2016 2:00 am

At this point, we bought a digital camera. 11 years ago they were still quite expensive!

The wing was fully plug welded (I don't have a spot welder). There is no filler at all in the wing panel or on any of the seams/welds. What you see here is the steel panel exactly as it came from Jeff. I never did understand why so many people said the panels weren't right. Mine was spot on.
Attachments
Archie osf wing fitted not in paint.jpg
Archie osf wing fitted not in paint 2.jpg
Archie osf wing fitted not in paint 3.jpg
archie lights bumper indicator no primer.jpg
archie lights bumper indicator no primer 2.jpg
Archie OSF wing fitted.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sun Jun 05, 2016 2:05 am

More of the fitting details for the front wing. When I painted all this lot in primer I rather foolishly did not wear a mask, it took several days for the red dust to clear off my chest - NEVER AGAIN!!!!
Attachments
Archie OSF wing top view of plug welds.jpg
archie osf in the metal.jpg
Archie shiney osf wing.jpg
archie full shot osf wing on.jpg
archie osf wing primer.JPG
archie osf wing primer no lights etc.jpg
archie osf  close up.JPG
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Re: Adventures in Welding

Post by The Nun » Sun Jun 05, 2016 3:46 am

impstress2003 wrote:. What you see here is the steel panel exactly as it came from Jeff. I never did understand why so many people said the panels weren't right. Mine was spot on.
Its not Jeffs panels they mean when many folk say they dont fit though, Jeffs stuff was pretty good, as you say.
Thing is Jeff used his own panels for his own work so he made sure they were ok, unlike some who make these items but never have to use them themselves so never find out just how much work they take to fit properly.
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Re: Adventures in Welding

Post by tiker » Sun Jun 05, 2016 10:41 am

You've had a steep learning curve but it looks like you have done it well, its hard to rebuild when you can't see was was there to start with, great thread keep going
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Re: Adventures in Welding

Post by impstress2003 » Sun Jun 05, 2016 5:29 pm

After getting the o/s/f wing done I decided to tackle the o/s/r suspension turret. When I started unpicking the previous repairs I found six (!!!) layers of plates which had been fitted over the original inner wing and turret. Unfortunatley all the original rot was still there, and the repair plates, whilst welded onto the inner wing, were not welded onto the cup the spring sits in.

The rot here was really bad. I made an initial repair section for the rear stiffener panel (shown here) but it was no where near big enough. More on that later.
Attachments
archie more osr inner wing rot.jpg
archie osr hole on the inside.JPG
archie osr inner chassis rail made up.jpg
archie osr inner more rot inside.jpg
archie osr inner wing horror larger area.jpg
archie osr inner wing horror second close up.jpg
archie osr inner wing horror.jpg
archie osr inner wing horror2.jpg
archie osr knackered spring cup.jpg
Archie.JPG
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Re: Adventures in Welding

Post by The Nun » Sun Jun 05, 2016 9:05 pm

Very interesting to see that, i havent ever seen an IMP in so bad a state on the rear suspension turrets as youve got there, theres virtually nothing left to reference from. :?
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Re: Adventures in Welding

Post by tiker » Mon Jun 06, 2016 1:26 pm

That looks a real mess looking forward to see how you fix that as Peter said there's no ref left ?
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Re: Adventures in Welding

Post by Lars Hagermark » Mon Jun 06, 2016 5:33 pm

:shock:
You're certainly pushing the "too far gone" very far from its hitherto interpretation. Love to see it can be done. :D
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Re: Adventures in Welding

Post by impstress2003 » Mon Jun 06, 2016 10:06 pm

This part was really hard for me to fix at the time. You couldn't buy anything for repairing the inner wings with and there were no spring top cups available. In addition, the car was so badly rotten there just wasn't anywhere I could start. I had so few bits of original steel to refer to for positioning and so little steel I could weld to I had to really think my way around it. I did lots wrong in fixing this but it has informed all the turrets I've fixed since. Looking back, cutting a section from another car would have been ideal but I think that if an Imp hasn't rotted here, it's probably worth saving!

In the next shots you will see some appalling welding on the rear chassis rail. Complete pigeon droppings. At this point I realised a few things.

1. The steel really truly does have to be properly clean to weld it. Even having weld through primer in the mix will introduce impurities which will make it near impossible to get a good weld.

2. This was going to be a long project. Time to take out the engine, etc, and strip it out - ie. do a proper job!

3. Get a good weld pool going and don't be afraid to keep the power on - especially if distortion isn't an issue. This splattery weld was in part the result of me doing it in lots of short bursts to avoid setting fire to the underseal behind it...! (again - clean everything first!!!!!)

4. Weld, like any liquid, is subject to gravity, and if you can get it to work for you then you should!

Fear not, I cut out the bad weld and replaced it, it was really not up to the job.

I didn't get many pictures of the first part of this work. I made a spring cup myself - not pretty, but functional and very strong. Again, I was still doing everything in small sections but in this case this was for two reasons. First of all, I couldn't make the complex shapes needed here. I have no English wheel or bead roller. Secondly, I didn't realise quite how much you can work steel with hand tools, so I tended to cut/weld rather than beat/form. I started by cutting back to strong steel around the top, and then removing the inner stiffener panel under the seat. This just revealed a lot more rot - the end of the seat pan was shot. I also found that the stiffener panel itself was rotten. To cap this, even the damper H-bracket which is made from 2mm steel had rotted through.

I repaired the damper H-bracket using a section of steel cut out of a scrap wishbone as I didn't have anything else thick enough!

I then replaced the steel working downwards. The complete stiffener panel had to come out, it was rotten from end to end.

This piece of work marked the start of my weld quality improving - it was bound to eventually, I was getting a lot of practise. I was definitely getting more confident.

There are a few pictures so I'll load some more tomorrow. When I started I just wanted to get on with it so I didn't get pictures of the first pieces I did. Hopefully you can see the state of the seat pan here.

Loading the pictures is driving completely and utterly nuts. For fifteen minutes I have been trying to load them but if just one fails I lose the whole lot!! Can anyone suggest a way to attach more than one picture at a time? I will add them in separate posts as it will reduce the chances of losing them. :)
Attachments
spring cup2.jpg
impstress2003
Posts: 365
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Mon Jun 06, 2016 10:07 pm

More pictures
Attachments
Archie osr inner wing started.jpg
OS Seat pan, repair section trial fit.jpg
impstress2003
Posts: 365
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Mon Jun 06, 2016 10:08 pm

Basically the whole last 15" or so of the seat tray was peppered with holes.
Attachments
OS Seat pan, before I started.jpg
OS Seat pan rot cut out first bit.jpg
impstress2003
Posts: 365
Joined: Tue Sep 09, 2003 10:00 am
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Mon Jun 06, 2016 10:10 pm

more...
Attachments
rear seat pan first bit tacked in.jpg
arch seat pan+inner wing osr2.jpg
impstress2003
Posts: 365
Joined: Tue Sep 09, 2003 10:00 am
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Mon Jun 06, 2016 10:13 pm

In some of the shots you can see the old inner wing still in situ. I left it there as long as possible as a reference. There was so little I could use to be sure that the steel was going back in the right place. Once the new section was in, this became the reference and I was able to remove the rot I had been referring to!
Attachments
arch seat pan+inner wing osr3#.jpg
arch seat pan+inner wing osr7.jpg
impstress2003
Posts: 365
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Mon Jun 06, 2016 10:15 pm

more...
Attachments
rear seat pan in progres general shot.jpg
rear seat pan, final bit tacked in.jpg
rear seat pan, final bit tacked in 2.jpg
impstress2003
Posts: 365
Joined: Tue Sep 09, 2003 10:00 am
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Mon Jun 06, 2016 10:16 pm

Seat pan all back in one piece - it was tricky unpicking it from under the seat end pocket. Upper part of the inner wing back together. Rear chassis rail and damper H-bracket fixed. New rear spring cup fitted.

Not the best job, but it's not hiding anything and it's all fully seam welded. Wait till you see the passenger side!!!

Inner stiffener panel next.
Attachments
Archie rear seat pan finished.jpg
The Nun
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Car Model: Imp x 2
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Re: Adventures in Welding

Post by The Nun » Tue Jun 07, 2016 5:19 am

Did you ever think perhaps i should go and find a better shell at any point? Ok if the cars been in the family from new , very rare, unique in same way like one of first or last and you feel some sort of attachment to it?
Good for welding practice though as you say and a sense of achievement in bringing something back from the dead and shows what you could do if youre determined enough.
Hope you manage to get it completed and see it back on the road and its interesting to see you doing it too of course for all us here :D
Peter Nunn...ey im member 00033
impstress2003
Posts: 365
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Tue Jun 07, 2016 7:39 pm

Finding a better car would have definitely been less work, but a lot of the point of this project was to learn the skills. It's a lot more engaging doing this on a car rather than with pieces on a bench. With respect to references, I was a little concerned about how to ensure that the spring cup went back in the correct place. In practise, the cup welds onto the bottom of the damper H-bracket. This was mostly sound so I knew the height it would fit at. The damper H-bracket is also radiused so the cup will only fit on it at one angle, so I had the height and the angle sorted. Front to back, I fitted the cup relative to a mark I made on the H-bracket, so I knew it was as far forward as it should be. Finally, to get the correct positioning left to right, I measured how far out from the side of the damper H-bracket the cup should protrude. It's never going to be spot on, but with what I had left, this was the best I could do.

So. Next I made a new inner stiffener panel. In order to fit it I left a hole in the inner wing to feed it into so that I could locate it behind the door pocket panel.

Making a complete panel on the bench and then fitting it was a much nicer experience than welding things up in situ and I'm sure it gives much better results.
Attachments
trial fit rear inner chassis rail os.jpg
impstress2003
Posts: 365
Joined: Tue Sep 09, 2003 10:00 am
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Tue Jun 07, 2016 7:40 pm

I tacked and trial fitted it a number of times as I went along
Attachments
trial fit rear inner chassis rail through pocket os.jpg
os rear inner chassis rail tacked together.jpg
impstress2003
Posts: 365
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Tue Jun 07, 2016 7:42 pm

Getting there
Attachments
os rear inner chassis rail tacked together overview.jpg
os rear inner chassis rail seam welded trial fit.jpg
os rear inner chassis rail seam welded through the pocket.jpg
impstress2003
Posts: 365
Joined: Tue Sep 09, 2003 10:00 am
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Tue Jun 07, 2016 7:43 pm

Panel made!
Attachments
rear inner chassis rail seam welded overview.jpg
rear inner chassis rail seam welded overview.jpg
impstress2003
Posts: 365
Joined: Tue Sep 09, 2003 10:00 am
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Car Model: Various Hillman Imps

Re: Adventures in Welding

Post by impstress2003 » Tue Jun 07, 2016 7:50 pm

Next up, I plug welded in the chassis rail and started the repairs on the inner/outer inner wing tub halves. I didn't get many pictures of this, I was just trying to get it done.
Attachments
PICT0004.JPG
PICT0002.JPG
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