Thepowerofdiesel - Project 165

Thanks guys

TIG dont know if it was the right decision for the sills and floor, seems to be more of pain than mig would be. It is the first lot of TIG welding I have done though went out and bought a TIG welder especially for this, another reason for being slightly mad. Wanted to keep the beads in the floor strength is a big issue and looking original as possible would be nice.


Really I think she should have been scrapped, but thats more of a reason to get it back on the road. Wont be a perfect factory finish so I wouldnt get to excited, there are just too many things that need replacing to be factory standard.

 

Had a good fight with the floor and it decided to fight back, slowly winning.






Seen as its been the first dry day in a while though its was best to spy my chance and turn her around to make it easier to work on the other side. Also welded a bit more of the floor in, which with luck shall be finally finished tomorrow. Bout time I hear you say

 

The goal was to get the floor finished this weekend. After a bit of a lie in we set too, all I can say Job done Will need seam sealing to make sure no water can get in before a nice thick coat of a "dontgofeckingrustingagain" product.





Floor done thought I would have a go at the sill shouldnt take long after all this was the better side wasnt it :think:
Front part went well.






Then to the back part and :doh: at this point I would like all gen 4 owners to take note and when possible get something around yours to stop this happening. Utter nightmare cutting more away than I expected. Well we're heading the right way just thankfully the outer sill was rusty and I had to cut it out otherwise I would never have seen the state of the inner. Only problem now is think I may have to get some more steel, underestimated :lol:

 

Thanks guys for the kind words.

Spent an hour or so the other night and all I have to show for it is this, I hate trying to bend 2mm plate its official!






Getting there with the sill, a bit excited we nearly have 2 sills and a floor again!

 

Sills are finished just the rear corner and arch to sort. Which will leave just the fiddly little holes around the boot, bulkhead and front screen. After that there will be a seam sealing session





Just a reminder what it looked like, seen as I forgot to take a picture before I started hacking away







Ok so are we all sitting comfortably? Then I will begin


Start where I left with the back corner, formed and welded the plate in.




Job done.


Hole in the spare wheel well next to the drain hole so bugger it weld that up as well




The hole in the boot





Started on the bulkhead next








Transmission tunnel




Spent the rest of the time hacking away at the other holes.









Just them to weld up really, then a couple around the front screen.

 

Your right it is rough! Was a right pain to do just couldnt get the car at the right angle to weld it and be able to see at the same time Dont worry though all the weld will be getting smoothed over no matter where they are, dont want to grind too much away you see for fear of weakening it too much.

 

Little holes filled.





The other one filled






And another, reckon most of the welding will be done by the weekend






Boot nearly finished, just a couple more small holes left. Should really start finding my suspension bits along with rear diff and subframe, so I can get them painted and back on some wheels.






Well well, thats all the holes in the shell welded then Will just have the front wings to weld, may have a go at that tomorrow seen as my Por15 is yet to turn up.






So pulled her out to spin her around and blow off all the grinding dust that has accumulated, also sprayed what remained of my vactan seen as the weather was so nice.