Adventures in Welding

Show off and tells us about your car, finished or a work in progress

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impstress2003
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Re: Adventures in Welding

Post by impstress2003 » Mon May 29, 2017 8:24 pm

Fitting the fan housing to the pump.

Note all the bolts now come through from the fan side towards the pulley.

The bolts are greased to prevent them seizing, but they are stainless so shouldn't give trouble.
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Re: Adventures in Welding

Post by impstress2003 » Mon May 29, 2017 8:29 pm

Next up, fitting the pulley. Again, the woodruff key must be fitted first. The key was smeared with grease and pressed into place with grips. The pulley was fitted and tightened, again using a lever through two bolts at the rear.

I will stress that you mustn't lever against the plastic blades to tighten anything, they will just break!
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Re: Adventures in Welding

Post by impstress2003 » Mon May 29, 2017 8:30 pm

Fit the fan:
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Re: Adventures in Welding

Post by impstress2003 » Mon May 29, 2017 8:32 pm

Next up, fitting the hose and the dynamo strap.

The dynamo bolt was coated in copper grease to prevent corrosion, and a very thin film of rubber grease was put onto the pump stub to protect it from corrosion:
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Re: Adventures in Welding

Post by impstress2003 » Mon May 29, 2017 8:34 pm

The finished assembly!

Ready to join the rebuilt engine and ancillaries:

Just noticed that I've gone over two pages again today - there are a lot of new pictures on the previous page too.
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Re: Adventures in Welding

Post by ImpManiac » Tue May 30, 2017 10:10 pm

You did a lovely job on the pump, Simon! :D

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Re: Adventures in Welding

Post by Pog » Mon Aug 21, 2017 12:05 pm

Excellent write up on the pump, I picked up one from this years National that will need a full strip down. Your photos make it look like something I could manage myself :)

Many thanks,
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Re: Adventures in Welding

Post by chris d » Mon Aug 21, 2017 7:35 pm

great useful writeup simon
do you have any pics of the disassembly
I have a couple of pumps to do but am struggling to split them
woodruff keys removed but there still not splitting
cheers chris d
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Re: Adventures in Welding

Post by oli » Tue Aug 22, 2017 6:25 am

Soak them in paraffin for a week.
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Re: Adventures in Welding

Post by The Nun » Tue Aug 22, 2017 10:26 am

Good how to on the pump, my seals supplied were different to those you used there though.
Someone had had a go at my pump previously too and it wasnt particularly brilliant job either.
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Re: Adventures in Welding

Post by impstress2003 » Sun Oct 22, 2017 9:29 pm

Finally got time to get on with the welding for the first time since January!

Not much but it's a start, hoping to build up some momentum again...

Opted to seam weld it, I built up in 1/2" runs and joined them together to minimise distortion.

Next time I dismantle a pump I'll get some pictures. :)

Building up welds between tacks:
IMG_5607.JPG
Seam welded, needs attention from the flap wheel:
IMG_5608.JPG
IMG_5609.JPG
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Re: Adventures in Welding

Post by MattorMatty » Tue Oct 24, 2017 9:06 pm

Great work Si! How much more welding have you got left to do?

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Re: Adventures in Welding

Post by bazzateer » Wed Oct 25, 2017 12:41 pm

Nice work Si
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Re: Adventures in Welding

Post by tiker » Wed Oct 25, 2017 5:18 pm

It's looking good I struggled with the rear corner ended up buying a corner of Malcolm but yours looks good
Keep going now :-)
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Re: Adventures in Welding

Post by colimp66 » Thu Oct 26, 2017 8:44 am

Very nicely done.

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Re: Adventures in Welding

Post by AnonymousUser » Thu Oct 26, 2017 8:48 am

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Re: Adventures in Welding

Post by John Simister » Thu Oct 26, 2017 9:30 am

The problem with the rear corners supplied by Malcolm (my car has two of them) is that they lack the convex curve from the base of the wheelarch to the rear end. To get the shape right involves more filler than is ideal. The Expressed Steel ones are better - I wish they had been available when my car's bodywork was being restored.
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Re: Adventures in Welding

Post by The Nun » Thu Oct 26, 2017 10:20 am

Its certainly a lot easier now to repair an IMP in the proper manner so it looks correct than it was only a year or so ago thats a fact.
Trying to make near enough sections fit right is a very costly and time consuming job, (and patching in can even overtake the cost of the newly available complete panels now on the market if done by a body shop).
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Re: Adventures in Welding

Post by John Simister » Thu Oct 26, 2017 11:11 am

The Nun wrote:Its certainly a lot easier now to repair an IMP in the proper manner so it looks correct than it was only a year or so ago thats a fact.
Trying to make near enough sections fit right is a very costly and time consuming job, (and patching in can even overtake the cost of the newly available complete panels now on the market if done by a body shop).
Very true, as I discovered to my considerable cost.

This was a fairly early stage in the repair, btw. It was all properly seam-welded after this initial tacking. Notice the straightness of the rear corner's bottom edge, which needed to be plumped-out a bit.
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Re: Adventures in Welding

Post by The Nun » Thu Oct 26, 2017 12:34 pm

Maybe a rear mud flap might disguise that fact a little? , but it's only really noticeable if you ever knew how it was originally and 95% of folk haven't really got a clue on that looking at some repairs done I've seen in a lot more visible areas of the car like the bottoms of the front wings and the rear wing sill sections?
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Re: Adventures in Welding

Post by AnonymousUser » Thu Oct 26, 2017 1:43 pm

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Re: Adventures in Welding

Post by tiker » Thu Oct 26, 2017 1:52 pm

John Simister wrote:The problem with the rear corners supplied by Malcolm (my car has two of them) is that they lack the convex curve from the base of the wheelarch to the rear end. To get the shape right involves more filler than is ideal. The Expressed Steel ones are better - I wish they had been available when my car's bodywork was being restored.
I had this same problem Malcolm said you have to clamp the back and then bend it round the rear arch under tension
I was a bit sceptical but it did work and it does then produce the curvature, more are less I think the biggest problems are that it is there you have to weld it and that doesn't help
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Re: Adventures in Welding

Post by AnonymousUser » Thu Oct 26, 2017 2:14 pm

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Re: Adventures in Welding

Post by tiker » Thu Oct 26, 2017 2:40 pm

I see what you mean.
They must all be one offs
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Re: Adventures in Welding

Post by AnonymousUser » Thu Oct 26, 2017 8:53 pm

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Re: Adventures in Welding

Post by tiker » Thu Oct 26, 2017 9:41 pm

Lesser men would have given up,
Iam thinking about it!! :-)
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Re: Adventures in Welding

Post by The Nun » Fri Oct 27, 2017 6:22 am

That's the secret to a good body resto, pick your panels doors etc that you will have fitted when the cars done and work with those always, swopping panels halfway often means they no longer fit, they weren't made like today's car using laser technology to 0.1mm IMPS were made when it was still shot gun and anvil type of thing
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Re: Adventures in Welding

Post by AnonymousUser » Fri Oct 27, 2017 8:12 am

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Re: Adventures in Welding

Post by impstress2003 » Tue Oct 31, 2017 10:53 pm

Hi John, yes, I formed the rest of the lower rear wing under the back lights myself using the shrinker/stretcher. It took some fettling but I'm pleased with the result! :D The club spares panels don't cover this section so I had to make this.

I've always used either club spares lower half wings or expressed panels for the precise reason that John Simister called out - the hand made lower rear corners serve a purpose but you can easily spot them when fitted, and with the amount of effort they take to fit it is always best to start with the best possible panel you can get. The hand made ones just don't have the convex double curve. If you think about it though, for what is charged you can't reasonably expect over an hour of labour to have gone into them - it's no wonder you can spend 4-5 hours of your own time to adjust a panel like this to fit something like.

In one of my pictures it looks a bit like the bird bath repair I made is overhanging the rear transom - it's not. When I bolted in the rear transom to line up the wing/engine cover/repair section, I trapped a piece of scrap steel into this joint to replicate the thickness of steel which will be added back in when I put the lower return onto the outer wing below the transom bolts. You can just see this piece of scrap sticking out. When I've fitted the return I will refit the transom and get another picture to show the line-up of all the repair sections/panels/transom.

Even with the club spares panel I did quite a bit of work. I had to make a fillet to go under the back lights - it's always rotten there. I also had to extend the bottom lip of the rear wing to cover the inner wing. Only about 1-1.5" wide, but essential none the less. This was butt welded on and flap disc'd smooth - but before I fitted this strip I used the shrinker to pull the panel into shape here and reduce some of the bagginess from the edge of the original pressing. Fitting the fillet strip after this disguised this work well. I also had to use the shrinker down the b-post seam to give the panel sufficient radius. I also used the shrinker on the arch lip in a few places to give the panel proper shape. I also very carefully increased the angle of the first swage by hand, using grips to make it match the profile of the door - I had to do this along the whole length of the panel.

I've almost finished welding this on now - I've had a couple more hours on it over the past week or so. The top seam is completely welded, the b-post plug welds are done, the sill-rail plug welds are done, and the wheel arch plug welds are done (one or two at the lower rear of the arch need a bit of further work). I just have to weld the outer wing onto the inner wing along the bottom of the bird bath, then I can finally say this panel is fitted.

In the picture looking into the inner wing tub you can see my next piece of work. The seam between the inner and outer halves of the inner wheel tub is puffed up/swollen with rust. Where the panels overlap water/salt has been trapped and it's tried to rot its way out - so I expect I will have to cut out a narrow strip around the perimeter of this seam and let in a new section. It will probably only be 1/2" wide. Then I'll finally be able to say the welding is finished on the inner wing tub! Then... I will have to make the small return on the outer wing which fits around the rear transom bolts. Then I can say the welding on the n/s/r quarter will be finished!

Pictures below...
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Re: Adventures in Welding

Post by AnonymousUser » Tue Oct 31, 2017 11:14 pm

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Re: Adventures in Welding

Post by ImpManiac » Wed Nov 01, 2017 2:20 pm

Lovely work, Simon! :D

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Re: Adventures in Welding

Post by Dave ' Linwood ' Lane » Wed Nov 01, 2017 4:29 pm

top work right there :D
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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 01, 2017 8:34 pm

Thanks for the kind words. At last I have finished welding the near side rear outer wing!

The bird bath to inner wing bottom edge has been stitched on rather than plug welded. I have also sorted the last of the plug welds on the arch lip, and made/fitted the return section which goes in the joint with the transom. All I have to do now is flap disc down the welds and fill/sand etc. But that can wait! Next work will be the joint between the inner and outer halves of the inner wing tub. Unfortunately I can already see that the seam has gone through so this will need cutting out and replacing.
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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 01, 2017 10:16 pm

Thinking about it, just to fit the outer wing repair panel - just the panel supplied by club spares - took 66 plug welds and over 6 feet of seam weld. Five and a half feet of which was built up first as tacks every inch and a half or so, and then built up entirely in runs of not more than 1/2 inch, all joined together, to stop heat distortion.

I dread to think how many plug welds and feet of seam weld have gone into this in total! Nuts!
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Re: Adventures in Welding

Post by 617sqn » Thu Nov 02, 2017 7:15 am

A nice selection of spare engines showing too :D

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Re: Adventures in Welding

Post by The Nun » Thu Nov 02, 2017 10:03 am

617sqn wrote:A nice selection of spare engines showing too :D

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Bet theyre all Greetham 1200 units too :D
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Re: Adventures in Welding

Post by AnonymousUser » Thu Nov 02, 2017 10:09 am

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Re: Adventures in Welding

Post by impstress2003 » Fri Nov 03, 2017 7:20 pm

Got started tonight on the seam around the centre of the near side rear inner wing tub. As planned I cut back the overlap. Before cutting I could see the seam was quite swollen and clearly full of rust. Once I trimmed off the 1/4 or so of overlapping metal there was loose rust everywhere! I took the knot brush to it and the holes started to grow. It's paper thin so I'm cutting out about a foot and a half and replacing it:
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Re: Adventures in Welding

Post by AnonymousUser » Fri Nov 03, 2017 8:32 pm

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Re: Adventures in Welding

Post by impstress2003 » Sat Nov 04, 2017 6:53 pm

Cut out... new section tacked in, starting to seam it at the bottom. All butt welded.
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