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 » Sat Aug 13, 2016 7:20 pm

And a spring cone. This was actually the other one of a pair I had made when I repaired the off side. I've made a lot of these since and never made them the same way again - I now fold them mostly from a single piece of steel and just weld in fillets where required. Welding is a great hobby, you never stop learning/improving :D :D :D :D

Once again it is already drilled/punched for plug welding. I know it looks excessive but this pattern is actually copied from a production welded turret I removed from a car - there are the same number of spot welds from the factory as there are here in my repair panel!
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178S.jpg
176S.jpg
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Re: Adventures in Welding

Post by Dave ' Linwood ' Lane » Sat Aug 13, 2016 7:23 pm

IMPRESSIVE WORK :o
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Re: Adventures in Welding

Post by bks974c » Sat Aug 13, 2016 8:02 pm

Must have been an early rootes car as I can tell you later cars have nowhere near this number of welds.

Nice work as previously said.

Scott
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Re: Adventures in Welding

Post by impstress2003 » Sat Aug 13, 2016 8:02 pm

Thanks Dave!!

Next I cleaned up the section of the inner stiffener panel I had removed. The holes I drilled to remove it were used to plug weld it back into place. The top side and mounting return were completely shot so I cut them off and made new sections later. This was some years ago though and I didn't yet have the shrinker stretcher!

With this I had a kit of parts to put it all back together.
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181S.jpg
180S.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sat Aug 13, 2016 8:46 pm

First, I welded in the inner wing tub repair section. I positioned it (wedged in place with chisels) and then tacked it prior to full welding. For the most part it is butt welded so the welds can be cleaned back flat if desired, but I probably wont. When it's finished I quite like the thought of it bearing its scars, this car has been through a lot! While doing this work I realised that the rear chassis rail was badly rotten so I did not weld this section through to the chassis rail - more on the chassis rail another time.
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184S.jpg
186S.jpg
189S.jpg
190S.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sat Aug 13, 2016 9:00 pm

Next up I fully seam welded in the repair section, and primed it.
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Re: Adventures in Welding

Post by impstress2003 » Sat Aug 13, 2016 9:08 pm

Next I repaired the inner stiffener panel.

I welded in the salvaged section as it was still very strong with no rust.

I then made a new top section and offered it up. Note that it is drilled for plug welding. The inner wing tub is also already drilled for plug welding through to it.

I cleaned off the primer from where this was set to be welded down, to be sure to get a good arc, and set to it!
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198S.jpg
196S.jpg
210S.jpg
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Re: Adventures in Welding

Post by impstress2003 » Sat Aug 13, 2016 9:13 pm

Finally, I welded on the new turret... job done!!!

:D :D :D :D :D :D :D
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Re: Adventures in Welding

Post by impstress2003 » Sat Aug 13, 2016 9:28 pm

I was really happy to reach this point because it meant that the car had become fundamentally pretty sound. Work to this point:

- Both heater channels
- Both inner sills
- Both outer sills
- Both floors
- All rear crossmember mounts repaired
- Both rear turrets rebuilt/replaced
- Both B-posts repaired
- O/S/F inner wing repaired
- New O/S/F wing fitted - this was supplied by Jeff Day and made on the same tooling as the club's new front wings! An excellent fit and highly recommended
- O/S A-post repaired
- O/S/F boot floor corner replaced

So this meant that all the rear suspension mounting points were completely solid, the floors were solid, sills were solid, seat belt mount points were solid.

The car probably hadn't been this strong since the 1980s!

I was a lot happier with the second turret repair than the first. The welds are a lot neater :)

Next... the n/s/r chassis rail :twisted:
Last edited by impstress2003 on Sat Aug 13, 2016 9:32 pm, edited 1 time in total.
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Re: Adventures in Welding

Post by impstress2003 » Sat Aug 13, 2016 9:29 pm

Just realised that because I posted a lot on this thread today, it may not be obvious that some of the pictures at the bottom of page two are also new today...
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Re: Adventures in Welding

Post by tiker » Mon Aug 15, 2016 6:40 pm

The car probably hadn't been this strong since the 1980s!
[/quote]


Probably not that strong when it was built
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Re: Adventures in Welding

Post by ImpManiac » Mon Aug 15, 2016 7:56 pm

:shock: Wow! That car really was far gone, wasn't it. Awesome work, Simon. Inspiring stuff. :)

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Re: Adventures in Welding

Post by GURNSIMPS » Sun Aug 21, 2016 2:54 pm

Just goes to prove that anything is repairable with the right attitude and determination,hats off to you Simon.
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Re: Adventures in Welding

Post by The Nun » Sun Aug 21, 2016 3:57 pm

Yep Id take my hat off to you too, if Id got one. :wink:
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Re: Adventures in Welding

Post by impmann » Wed Aug 24, 2016 2:41 pm

I have a huge attachment to this car due to the history I have with it... but even I would have thrown the towel in on repairing it. Massive respect to Si for saving this car.
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Re: Adventures in Welding

Post by Lars Hagermark » Wed Aug 24, 2016 3:49 pm

Image
No car, or remains of one, will offer a valid excuse now. :wink:
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Re: Adventures in Welding

Post by The Nun » Wed Aug 24, 2016 5:27 pm

impmann wrote:I have a huge attachment to this car due to the history I have with it... but even I would have thrown the towel in on repairing it. Massive respect to Si for saving this car.
Perhaps he will donate it back to you once finished, we know theres quite a few kind and generous IMP club members around, as with the replacement Cali badge? :wink:
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Re: Adventures in Welding

Post by impmann » Thu Aug 25, 2016 1:29 pm

No chance! Its not his car, anyway... 8) :lol:
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Re: Adventures in Welding

Post by impstress2003 » Thu Aug 25, 2016 5:56 pm

Definitely not mine! Nikki had this before I met her! :shock:

No way we will get rid of it tho, there's 100s of hours gone into it already :?
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Re: Adventures in Welding

Post by ImpManiac » Fri Aug 26, 2016 4:50 pm

As above, this thread demonstrates that no car is 'too far gone to save.' :D It is a matter of will.

I shall take my hat off to you, Si, next time I see you and am wearing it. :?

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Re: Adventures in Welding

Post by 67cali » Sun Sep 25, 2016 8:53 pm

I think youve stolen the award for triggers broom from me.

Was great to hear all the work youve done on archie and the photos are a brilliant history file. Cant wait to see this car back on the road. Massive respect for taking on the job and what a skill youve learnt from it.
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 8:13 pm

Thanks for your kind comments!!

I found a couple of pictures of the spring cup from when I was making it. It's made in four pieces and fully seam welded now, this was a trial assembly of the parts prior to welding:
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SpringCup2.jpg
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SpringCup1.jpg (76.5 KiB) Viewed 11245 times
Last edited by impstress2003 on Fri Oct 21, 2016 9:52 pm, edited 1 time in total.
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 8:25 pm

So... fast forward a lot of years, and I got started on the car again recently.

Next up I got started on the chassis rail/rear section of the inner wing.

While welding up the spring turret I had noted that the chassis rail was rusty inside, and cleaning off the rust it was covered in pin size marks which would just bloom up in rust again a week later, so even though it was quite thick and felt solid, I decided it would be best to replace it. Looking further down the chassis rail I noted that the bottom flange of the chassis rail had rusted quite badly between the spot welds which had caused the metal to swell. This was so bad that the last two or three spot welds had actually pulled through the inner wing.

The inner wing had rotted badly and the inner and outer halves were barely held together, the seam where they meet was badly corroded and swollen. Looking from inside the car you can see that when I pressed on the seam just under the parcel shelf it went straight through :(

As mentioned before, the car was very flexible because of all the rot. The rear chassis rail was moving before I started the repair on the rear turret area and I think as a result the bottom radiator mount had cracked right through from fatigue!

There are a few shots below :
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InnerWing.jpg
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Chassis3.jpg
Chassis2.jpg
Chassis1.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 8:34 pm

So, I started by cutting back the rotten base of the chassis rail and cleaning up the inner wing.

I found that there was a definite line where the rot on the inner wing started, so I would have to repair the inner wing to this line later.
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ChassisCut3.jpg
ChassisCut2.jpg
ChassisCut1.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 8:39 pm

So the next thing I did was to make a repair section in 1.2mm steel. The shrinker stretcher was just about able to work the steel but I couldn't use anything thicker in it.
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ChassisRepair1.jpg
ChassisRepair2.jpg
ChassisRepair3.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 8:46 pm

Next up the chassis rail section was welded in. The section was fully butt welded so I could grind the welds down flat afterwards, as this is likely to be seen more often than a lot of the other repair sections.

I plug welded it through from the engine bay side because I had forgotten when I made the panel that I had already drilled the inner wing, so it got two sets of plug welds...!
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ChassisRepair1.jpg
ChassisRepair2.jpg
ChassisRepair3.jpg
ChassisRepair4.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 9:07 pm

So the next pictures skip forward a bit. When I get in a groove I don't stop to take pictures so I actually forgot to take any at all at the time!

I seam welded everything and then flap disc'd it all down prior to primer, except for the section which will be behind the engine bay cowls.
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RailFixed2.jpg
RailFixed1.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 9:16 pm

Next up I repaired in the rear inner wing tub. This was quite a large section and I plug welded it through to the repaired chassis rail. In addition, I seam welded it to the rear inner upright which goes behind the inner wing tub. This section as you can see in the pictures below was badly rotten also and needs the bottom 8" replacing, so I did not weld it back to this section.

Once again this was fully butt welded and I added the return flange on the bottom of it to align exactly with the original inner wing. I used a copper block under the weld to allow me to seam weld right to the end of the panel and then grind it back. When I originally fitted this section I made the flange a little wider than it needed to be which helped dissipate the heat and then I trimmed it back to size.
Attachments
InnerWing1.jpg
InnerWing1.jpg (88.46 KiB) Viewed 11232 times
InnerWing2.jpg
InnerWing2.jpg (82.52 KiB) Viewed 11232 times
InnerWing4.jpg
InnerWing3.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 9:25 pm

Next up... rear outer wing.

This was pretty dire, it had already had a cover sill welded to it, a wheelarch had been tacked into it, and the birdbath had been fitted with a repair panel which had been installed over the original, which was in better condition than the repair panel after 30 years or so... can't argue with it though, it did the job and kept the car going! Far better than it being scrapped! best bonus is I can re-use the rearmost section of the original outer wing in conjunction with the club panel to make a decent job of this.

Pictures of how it looked...

In the second picture the red primer section is the original wing which I exposed by unpicking the welds on the repair panel.
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OuterWing1.jpg
OuterWing2.jpg
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Re: Adventures in Welding

Post by impstress2003 » Fri Oct 21, 2016 9:36 pm

I cut off the outer wing so I could get full access to the inner grot. The inner wheel arch was well and truly shot :(

This is all I'll post for now, more to come though - inner wheel arch rebuild pictures when I get 5 minutes!

Edit: forgot to mention, at some point this car had big wheels on it and I found when the outer wing was cut off that the inner tub had been hammered out for clearance! You can sort of see it in the general shot of the inner arch but the rust is doing a good job of hiding it. :D
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GeneralShot1.jpg
GeneralShot2.jpg
Grot1.jpg
Grot2.jpg
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Re: Adventures in Welding

Post by 617sqn » Sat Oct 22, 2016 8:52 am

:shock: Blimey. As Tim says......

Fantastic effort and harks back to the original hand built prototypes :D

Looking forward to the next instalments.

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Re: Adventures in Welding

Post by Dave ' Linwood ' Lane » Sat Oct 22, 2016 9:09 am

This pic alone would be enough for me to scrap it off - well done for keeping going as id of given up by now
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Re: Adventures in Welding

Post by MattorMatty » Wed Nov 02, 2016 7:46 pm

Great work on that chassis rail repair! I'll be watching how you repair your inner wheel arches as I spotted on my Sport the other day that the outer and inner arches aren't even attach to each other.

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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 02, 2016 8:54 pm

Thanks Matt

On this car the outer arch was not at all attached to the inner arch. Before I started repairing the rear chassis rail I could move the bumper end of the rail easily one inch just with index finger. It was unbelievably weak - some of the next pictures over the next few posts will hopefully show why. (not sure I will get to post all of this today)

To repair the inner arch I decided to make my own using my shrinker/stretcher. I knew I would have to make it in a few sections so I decided that I would start by creating the inner arch lip and welding it on top and bottom. I could then fabricate the inner sections from front to back and work back to the new inner arch, which I used as a reference.

Anyway, a couple more pictures of before I started, and a shot of the state of the rear wing...!
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sill_end1.jpg
sill_end2.jpg
Rear_Grot.jpg
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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 02, 2016 9:01 pm

First up I started at the bottom front. I took a piece of steel, folded a return onto it and then using grips I radiused the opposite side of the piece. I then used the shrinker to pull it into shape so that I could seam weld it directly to the existing repair to the lower front inner wing tub.
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Front_lower1.jpg
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Front_lower2.jpg
Front_lower3.jpg
Front_lower4.jpg
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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 02, 2016 9:08 pm

Next up I went to the lower rear section. I had already fitted a large inner repair panel which I had welded to the rear inner wing, so I had something solid to weld it to right at the bottom. However, at the upper end, I cleaned back the original inner wing and tacked it on as a reference.

I used the shrinker/stretcher to make this repair section too, and made it based on a factory inner wheelarch I was lucky to buy about 10 years ago but did not use! I then checked it inside the new wing before finally tacking it in place.
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Rear_lower1.jpg
Rear_lower2.jpg
Rear_lower3.jpg
Rear_lower4.jpg
Rear_lower5.jpg
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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 02, 2016 9:15 pm

Next up, I made a fillet to fit between the new arch and the repaired inner wing tub. It was cut from flat sheet, then I used pipe grips to radius the steel. I then used the shrinker/stretcher again to put in the compound curves, and pull the steel into shape. It fits all around within 1 mm and will be fully butt welded when finished. I have fitted it but forgot to take any pictures of it tacked into place when I did this step:
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Rear_lower1.jpg
Rear_lower2.jpg
Rear_lower3.jpg
Rear_lower4.jpg
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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 02, 2016 9:17 pm

Next up I made the missing section of the inner arch lip, and welded this into place. This allowed me to start cutting back the rotten inner wheelarch:
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Arch_Lip1.jpg
Arch_Lip2.jpg
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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 02, 2016 9:23 pm

Next I made the first of the fillets to fit between the solid part of the tub and the new outer arch. Once again, the fit is to within 1mm for welding. This has a lot of radius on it and a raised lip, so I curved the steel by hand and using pipe grips, then I used the shrinker/stretcher again to put in the compound curves.
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ap1.jpg
ap2.jpg
ap3.jpg
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Re: Adventures in Welding

Post by impstress2003 » Wed Nov 02, 2016 9:27 pm

Finally, I made the last piece to fill-in between the solid inner tub and the new arch lip. There's a shot below to show how close the fabrication is here. All tacked together... just needs seam welding. All of it can be butt welded and flap disc'd down flat...

Didn't get too many pictures, I was in a groove again!
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ao1.jpg
ao2.jpg
ao3.jpg
ao4.jpg
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