Chris_C wrote:Unless something of a miracle happens today, I won't be making it to the BKV First I'll have missed in 5 years

May your autojumble stands be full of green books and cavity covers and may you all take the mick out of Foggy for running out of petrol/not having a working 300/having a super slow FWD daily.

I'm back to the welding... just in case

ah unlucky dude.

cultivate the beard for next year.

Oh Dear,welding.........

Me,no likey.

On a plus note I'll be starting on the Bronco shortly.
Never moved for 15 months but seperate chassis eleviates the problems you have.

My biggest problem will be making 7 into 8.Damned misfire.

Anyhows,goodluck.

You'll be starting your own fab company with all the practise you're getting.

Cheers gents.

Today went... erm, well, not great I guess. I'm not making it to the BKV

However, I've found more problems (read holes). Whilst this has taken more time I can't complain. I drive the car hard and on rally's I can't afford for something to not work properly if I did stuff it so I guess it's for the longterm good.

I'll upload some more pictures soon.

Chris_C wrote:Cheers gents.

Today went... erm, well, not great I guess. I'm not making it to the BKV

However, I've found more problems (read holes). Whilst this has taken more time I can't complain. I drive the car hard and on rally's I can't afford for something to not work properly if I did stuff it so I guess it's for the longterm good.

I'll upload some more pictures soon.

Time welding is time well invested dude.

Sod the holes, just put the wings back on and come to the BKV - it won't win anything anyway!

I can't bud, this welding\apprenticing\borrowing welder is being done at my favourite price, I need to fit round his schedule.

Pics from yesterday and today:
Start building up the flange


Then infill

Splat to hell


Then grind into the right shape

Turn up lip to flange

Make new wing clip hole and slot, and new flange

And we look better again


Cut out equal bits of flange from the wing itself


And back to wing A.

Before

After

I'm really really happy with that. Do I have to bolt the wing back on!?

Looking good bud!

cheers

James

That's hardly rusty at all Chris, if you can make a patch rather than having to make a whole panel then it doesn't count. When I'm back to working on metal cars instead of plastic ones I'll show you what proper rust looks like.

Looking good though

I hate rust.

If I'd seen 9 days ago what I know now, I'd have scrapped the shell this time. More pics to follow another day but I really don't want to look at them now.

So, instead, picture of something else

pcb of coolness dude.

Chin up man.
If anyone can do it, choo can doo eeet.

Eek! I thought you had it all under surveylance? Where...?

cheers

James

Right then, I've hidden from the pictures long enough. Fake was bolted back up a while ago (well, a week) tomorrow she get's pulled apart again (fuel tank dropping and a few other bits) for final welding.

Other side wing. I reckon these two inners are deserved of some kind of BKV prize of their own, *very* happy with how they came out

Random patch she had a while ago. Shame it was never painted. This was actually liquid, it all moved and squished.


So, cut out, and the box section was checked and the dubious cut. Patch made in 2 parts, one inside the car and the vertical of the box section and the other making up the rest of the floor and tying my seat back to the floor

And the underside of same

But being under the car just means we find more rust (note patch, and the fact the silly tiny 'L' section no longer exists since the structural screwdriver got there


Right, back to the other bits.
Boot floor handbrake bracket rust


And, the prize of all the pictures.

Epic rust... don't let it fool you

So, out with the structural screwdriver

Hmmm, that looks like a squillion layers of metal... this is going to be interesting

From the outside... oooooh, recaro pimp.

Start cutting back to find sound metal

Nope, that wasn't enough. Moar. Note structural screwdriver

And now we've cut 6 layers (yes, seriously) away, we best put them back


Nearly there...

Drainage channels were blocked with crap to cause this and had taken out the bottom of the arch too...

Right, thats all the exterior panels then...

And interior. Note Chris' Cunning (C)inlet (C)holes

Stuck in




But, theres a problem with a million box sections and layers. How can you know you've got all of them? And painted the inside? Well, I normal coat panels with Hammerite No1 after being recommended it from a mate as it rust converts and primes and seems to be waterproof. Soooo, the best plan ever is to block the drain holes again, and fill the inlet holes until it's flooded. Then remove the blockages and collect excess paint! It did take 3 pots of it though

There was only a small amount of spillage

So it wasn't all that rusty after all then

Chris VS Rust.
Chris wins.

Rust sugests rematch some time in future.