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Originally posted by Holdenute
May I be so bold as to suggest that while you've got them in this state, you fix the cause of the rust in this section. That stupid little pocket that catches all the leaves, mud and crap. Maybe box it somehow?

Love your work by the way.

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The thought did cross my mind as well, and I almost went down that path.... However I wanted to see if I could follow the design and make pieces as close to factory as possible. After I'm done all of the areas I've repaired are going to get a decent splash of POR15 and then waxol the lot. Hopefully that will keep the tinworm at bay...

Mostly fixed up the nose (few pieces of rust etc.) and got it as straight as it will ever be. Today was a public holiday and I needed some cheering up so I the idea to hang some panels crossed my mind...





The corner isnt too bad (at least it's the best I can get it so far. I'm afraid that if I try and planish it too far that I'll ruin it since there are some areas which are quite heavily folded. Might just have to accept a bit of filler in this region.



Plan is to sort the gaps, figure out the bits that need cut and welded, then pull the hole lot to pieces, strip the hard to get places then crack out the dollys and panel file.

In the back of my mind I had the thought that the cowls weren't right, it was the first area I attempted to fix and I was a bit 'green' at the ol' panel beating at the time. Coupled with the fact that the patch panels I bout were rubbish the result is less than pleasing...





I mean I am only human after all...

So I lined everything up surrounding the region (i.e. glass,door, guard and chrome) and got to fixing it properly. The whole lot needs to be pulled down and slightly widened.



And this where we're at as of this evening.
Peace out...

You are correct, I think I might even have the issue. The guy is based in melbourne and there are a few vids on his website. Can remember the name for the life of me otherwise I'd throw the link up.

Haven't been able to spend much time on it this week but this is what we've accomplished since last time.

Two guards, file finish (give or take)



And about halfway through straightening this door

Right, progress this week (might be a bit of a novel, sorry).

I needed to get a new hard line made up for the trans since an old brazed repair finally gave way. Gave an auto transmission speciallist a call who have had previous dealings with (though not all good dealings). Told him I had the pipe and could bring it in to bend up up a new piece and flare the ends for the fittings. "um, ah well it's not really all that easy, ya really need the car to make sure it clears everything etc etc" yea I know that, bend it up close to the original and I can make it all fit, told him car isnt going anywhere at the mo "um ah well we really need to do it on the car, the last lot I made took 6 hours labour" 6 Frocking hours? wtf? I said yea rightoh, seeya. Went to another place, guy was good bloke, said I could just make up a rubber hose with fittings ($20 odd all up) and would give me a good deal on a trans radiator later down the track. Ended up talking about cars for the next 30 min.

Other than that, fixed some more rust



Attempted to make this bit in one piece, after 3 stuffed pieces thought stuff it and made it out of 3



Really happy with this repair, through a combination of hammers, dollys, shrinking disc and panel file this shouldnt need any sort of filler at all, mint.

Hey Allen, glad you're enjoying it and sorry to hear you're ill. Starting to turn cold over here (nothing between us and Antarctica when the southerly blows) so I've had the door of the shed closed.

More panelbeating over the long weekend....

Finally got the nosecone to a presentable state, I refuse to touch it anymore!



One of the rear doors is almost a write off (full of dents). I've pulled it off the skin to beat it out and fix up some problem areas, the jury is still out if I am able to save this (it's half done in the photo).



Though our cause is helped somewhat by the new toy, shrinking discs rule...



Also got on to the rear quarters, this is an example of what I'm dealing with. Previous person welding up the trim holes far too hot which has distorted and pulled the panel in to form a low spot



If you lose where you are with highs a lows, one way to get the constrast back is to cover the metal with perminant marker...



Top of the quarter is as good as I can get it...



Also pulled the skin back from the top of the door as you could see a whole lot of rust hiding below, wire brush and POR15 dealt to that

Glad you guys are enjoying this.

Well some good news and some bad news. Good news is that I might have a new shed to play in a month or so, bad news is that I may have to use some of the money I had earmarked for the paint job may need to used for part of the house deposit. Not sure what's going to happen but this project will not stall/be sold.

So pushing on...

Re did one of the repairs in the lower 1/4, purely because I wasn't happy with it. Final result is pretty good and will need way less filler than what was there, plus the welding is alot better.



POR15 the inner of the door frame



Also, back to the door skin I'm fixing. Decided the lower half of it was just too dented/ripped/rotten to warrent repairing. So in typical fashion I took a lower skin for a HQ front door I had sitting around and cut it up/bent up, to suit the skin. Laying it on the frame ensured it was sitting right and the ability to panelbeat it properly off the frame is a good way to ensure the steel is close to perfect as possible. If I had to fix a lower skin again I wouldnt hesitate to do it off the frame again.





Welded up the lower section for the skin, so glad I decided to do it properly, am getting sick of this door now.



Bit more hammer, bit more dolly and a bit more shrinking disc and we have a (generally) straight skin



Chucked it back on the frame ( plenty of seem sealer) and fixed up a few more bits...



Very happy to have this done, like the nosecone, I'm leaving it the hell alone!



Unhappy with another one of my old repairs I decided to redo it properly (the experience has definately helped me though)



Pick up another one of these too (they are bloody exey over here so if they are cheap I grab em!), the shafts on this one is siezed so will require a refresh and test.

Sorry that there aren't many photos with this but I accidentally deleted a lot off my camera, bugger.

Decided to go about replacing the sill properly. The rear internal braces all needed new metal and all of the internal cavity has been painted with POR15, should keep the tinworm at bay.

I hung the doors again to ensure my gap was even all the way across.





I had left a small 'lip' from the old sill so I could rest the new section on, also made it possible to screw the new section in and hold it straight as I welded it.



This area isn't crucial to get right (chrome strip goes over it), this is close to finished.


Welded it in fairly slowly but ensured the weld was plenty hot. Welding two panels in a 't' arrangement is a pain in the arse but lots of little 'c's get the best result.



Finished result isnt too bad, hasn't warped at all (thank goodness) and was able to hide most of the welds by grinding it back. A small amount of filler where it has slightly undercut in places will be all thats needed. Just a small section near the dogleg will finish it off.

nice work, your doing a great job!!

nzstato
What did you use to remove the paint on the panels? Paint stripper? Disc flapper?
Cheers
Keith

what the hell happened to that quarter panel? was all that hidden under bog?

i see some bottled amber muscle relaxant as well, lovely for inspiration. good job