Laurie's First Track Day Car

[BlackBox]

Re: Laurie's First Track Day Car

Laurie, could I ask a favour, could you measure the full length of the sill for me?

[easytrans]

Re: Laurie's First Track Day Car

Laurie, could I ask a favour, could you measure the full length of the sill for me?

N/S

| | <---- to where it peeps from under the wing 1605mm ------------------------> /
| <-- from where it curves around wheel arch/chassis/drain-tube 1720mm ----> /
|_________________________________________________ _________________/

IHTH

Laurie

[BlackBox]

Re: Laurie's First Track Day Car

Thanks, the steel bar new is 7.5m and I want to cut it to fit in the car with minimal wastage but no shorter then the sill as it comes new in the packet so to speak .... I guess then cutting at 1.8m will suffice .... thanks that's a great help ..

[easytrans]

Re: Laurie's First Track Day Car

So after some domestic (equine) work in the pouring rain this morning repairing and changing paddock fencing, I eventually got out into the barn and even then the water was seeping in through to the floor, our water table is so high here in Suffolk now that it just runs off over the top of the ground !!

Anyway, 5 hours and only small progress ......

Set to work on O/S inner chassis repair .....

The death of a thousand cuts !






Patchwork quilt tatty but this is my worst side having to weld left handed again ....



Then set about the O/S subframe section ......



Chopped out 2 layers down to the subframe ......



then added back the first layer .....



then the second ......



So that has secured the subframe to part of the lower bulkhead/floor. The plan is to slice through the section to the right of the new plate (with the wishbone mounting threads attached) but after the front to back cut I will tack the metal template onto the new metal as a locator for the mountings after I repair the floor ........



Finally the plan is to (maybe) add another plate of 3 mm steel to add extra strength to this area (though its much better already since just this repair).

Laurie.

[BenH]

Re: Laurie's First Track Day Car

Crikey thats some hardcore repairs ! I doff my cap

[Vinci]

Re: Laurie's First Track Day Car

I must say it looks very well!! Better than I thought would be possible without replacing the whole panel really!

[DarrenH]

Re: Laurie's First Track Day Car

solid work there chief, in both senses of the word.

no egg sucking intended, the two new squares youve welded in have deleted one of the drain holes. looks like that hole was the eye of the rust storm originally. chicken and egg thing i guess if you dont reinstate it

[easytrans]

Re: Laurie's First Track Day Car

Crikey thats some hardcore repairs ! I doff my cap

Cheers Ben, It's time consuming but rewarding when you get good metal to good metal .

I must say it looks very well!! Better than I thought would be possible without replacing the whole panel really!

Thanks Vinci, yes it's much better when that old rot was taken out, it always look's worse with all that rust forcing the panel lamination apart. It was a fiddly job with picking away at it bit by bit, if it was not a Sunday I'd been much quicker using the air chisel but trying to work quiet means lots of manual pulling twisting and wrenching

Laurie.

[easytrans]

Re: Laurie's First Track Day Car

solid work there chief, in both senses of the word.

no egg sucking intended, the two new squares youve welded in have deleted one of the drain holes. looks like that hole was the eye of the rust storm originally. chicken and egg thing i guess if you dont reinstate it

Yes indeed, those three small (not welded) holes are reassessed down with a ball-pein hammer to afford drainage from between the two layers and allow some anti rust treatment (oil or wax-oil) to ingress. I'll be adding some other drainage in that area also before the floor-pan goes on.

But always good for you to point these things out least I forget

Laurie.

[gte 16v]

Re: Laurie's First Track Day Car

Top work as usual, coming along nice, and at a rate of knots

[tonka666]

Re: Laurie's First Track Day Car

Good work looks like you have it all planned out. Sometimes when it is a big job like this you can just end up staring at it thinking how the hell am i going to sort that?

[easytrans]

Re: Laurie's First Track Day Car

Top work as usual, coming along nice, and at a rate of knots

Thanks for the comments ;-)

Sometimes when it is a big job like this you can just end up staring at it thinking how the hell am i going to sort that?

Believe me! theres still lots of that going on, but you have to kick yourself and just start chopping metal and see where it takes you. All too easy to spend time looking at the bigger picture and loosing focus. In the end its all getting repaired and I tell myself if I have to cut out something I welded sometime before along the way to resolve the next bit then so be it {at least it will be a strong bit I'm cutting into.. lol}.

Saying that the 1mm slitting blades on the angle grinder are a god send but I do fear for my life when one (or three) decides to explode when you catch an upright edge {thick gloves and safety glasses every time} 8-(

Laurie

[DarrenH]

Re: Laurie's First Track Day Car

Yes indeed, those three small (not welded) holes are reassessed down with a ball-pein hammer to afford drainage from between the two layers

ah ! internal mini sumps! that's a good idea.

i tend not to even look or acknowledge rot elsewhere on the car until its time! one of the true definitions of an introvert i have to concentrate on one task at a time from start to finish or i go mad in the head.

[easytrans]

Re: Laurie's First Track Day Car

So again only the afternoon to get in the workshop but though it may not look much I think got a good bit done ....

First screwed down my jig for the bolt mountings then moved it out of the way and cut out the next rotten pieces {blew up another slit disk no wonder they were cheap that's 3 exploded today and they don't last long when they do hold together "theses are Silverline ones BTW:"} .....



Made up and welded in the first layer (these parts like the rest are 2 layered) ....




Then a second layer welded in and the mounting threads re-located and welded .........




Then resolved the near edge (lower section) and added the upper section sharks teeth (to add strength to the item) and finished off the end .....




Decided I only need to replace part of the floor pan as so trimmed and measured up ........



Fabricated the bulkhead seam to floor section ......



Checked the fit and then welded in that section .......




Then puddle welded the seam and puddle & seam welded the lower bulkhead to that part ......

[


Where as I had planed to add some "extra" strength sections in it really is solid already and I think the boxing of the floor-pan around that wishbone mounting will provide more than enough strength.

I just hope I remember what I did in what order when I get to the next side

Laurie.

[BlackBox]

Re: Laurie's First Track Day Car

I take my hat off to you sir !!

Not a lot rot wise fazes me, but that was some repair work you had on your hands there ...

I bought 20 Silverline 1mm cutting disks two weeks ago and I'm having the same issues ... the last lot "Blue Spot" were fine.