From shonk to.......

[1800turbogte]

Re: From shonk to.......

Blimey I'v just caught up with this and someones been very busy. Very nice work Ben

Chris

[BenH]

Re: From shonk to.......

Cheers Chris, I've been busy yes but with other stuff unfortunately

[dancedj]

Re: From shonk to.......

Coming along nicely I hope my champion doesn't require as much welding

[BlackBox]

Re: From shonk to.......

It quite rough really, but fit's better than it did. So tacked it in, then make a start on welding.

Red Astra by ben a.k.a me, on Flickr

It's going to go a bit wobbly bob and will need some filler, but that's to be expected in all honesty. Normally bodyshops just tack them and fill over the top to save warping. I don't like that as they don't last well, so will be seamed all the way round.

I always wondered how peeps fully welded this sort of job without warping the heck out of panels ... they ans is they don't, fully weld that is.

[BenH]

Re: From shonk to.......

Coming along nicely I hope my champion doesn't require as much welding

Cheers and I hope not too!

I always wondered how peeps fully welded this sort of job without warping the heck out of panels ... they ans is they don't, fully weld that is.

Yeah I have migged in the past with very little warping, my most recent patches are miles ahead of the first ones I tigged. It can be done and is certainly a skill indeed, you can hammer and dolly it as it cools to stop it shrinking and twisting. I shall try more of this on this side and see how it goes, also I'm going to try hot shrinking with the oxy torch on this side afterwards.

Just repeat after me lol It can be done!

[mrdezzer]

Re: From shonk to.......

Top work on the welding Ben. You must have got through some metal now

[BenH]

Re: From shonk to.......

Top work on the welding Ben. You must have got through some metal now

Thanks About 1/3 of a 8x4 sheet so far and a fair amount of Argon, still lots more though

Edit..

Before I forget it's around 90.5 hours of work since I got it!

[BenH]

Re: From shonk to.......

A little more done over the xmas hols so far..

Started with this


Red Astra by ben a.k.a me, on Flickr

Then.. I also extened the sunroof drain out as well..


Red Astra by ben a.k.a me, on Flickr

Bit here too..


Red Astra by ben a.k.a me, on Flickr

Tied the seat belt mount into the box section, then filled it all in..


Red Astra by ben a.k.a me, on Flickr

Then much faffing with the fit of the arch again..


Red Astra by ben a.k.a me, on Flickr

Marked up for the correct place for the swage line, then used my new block to form it with a hammer..


Red Astra by ben a.k.a me, on Flickr

Not perfect but near enough, you can see a untouched arch underneath..


Red Astra by ben a.k.a me, on Flickr

I then spent a good while more wiggling it into the almost the correct shape, then ran a bead a of tiger seal round the inner arch edge and slipped it in to place..


Red Astra by ben a.k.a me, on Flickr

Then that got trimmed and tacked into place..


Red Astra by ben a.k.a me, on Flickr


Red Astra by ben a.k.a me, on Flickr

All ready to be welded in place now

[steven]

Re: From shonk to.......

Nice bit of work there,i see your panels are the same good fit as mine where

[BenH]

Re: From shonk to.......

Cheers, yeah they have been a pain but I suppose that just makes it more fun

[BenH]

Re: From shonk to.......

So got that seamed in, then mostly flatted off and cleaned down the panel. I'm going to be trying hot shrinking on this side, just to even out a few high spot's from the welding.


Red Astra by ben a.k.a me, on Flickr

I also folded over the arch lip so there is plenty of room for tyres now, I find if you roll it over then fill with tiger seal stuff. Before you finish rolling it over it seal them well against being a water trap.

Then jacked up the other side so it's level then stripped out a few more bits from inside to get to the front floor pans, I'll need to drop the engine and box out next to finish up the welding and get the last in the bay sorted


Red Astra by ben a.k.a me, on Flickr


Red Astra by ben a.k.a me, on Flickr

[tonka666]

Re: From shonk to.......

Nice work bud should be ready by 2015

[BenH]

Re: From shonk to.......

Haha summer this year should be doable...

[DarrenH]

Re: From shonk to.......

excellent

are they just inspection holes in footwells or you gonna box them in to the wishbone mounts ?

[BenH]

Re: From shonk to.......

Thanks

Well both front floor pans need replacing really, I just ripped them out a little to have a look. It's hard to tell from the pics but there are too many holes in them around wishbone mounts to just patch, that and the bottom of the bulkhead needs replacing. Engine out next so I have room to work give me chance for a proper look with the angle grinder...