I really need to start doing some serious work on this project, so I decided that I needed to so some metal work on it to get me motivated again. so my choice was to either modify a front panel for the bonnet
or try and make a couple of rear inner wheel arches
and the front panel won.
so this is what the standard front end looks like
with my car I decided that I want to remove the over riders, recess the grill slightly into the bonnet and reshape the grill opening.
as Im still a beginner at this sort of thing I thought I'd post up the trials of doing a simple project....you think its simple as you begin but it soon gets more involved.
so this shows the area to be modified more clearly
so the first thing I did was to cut out a small section to change the profile slightly and reweld it.
the first side I MIG welded,but then spent what seemed like ages grinding the weld back with a power file so for the other side I decided it was time to try some proper work with the TIG welder. Its definately more enjoyable than mig when it goes right, but you do need to work more accurately, and there is much less metal to grind back when finishing with the TIG,expecially with the more detailed areas.
so next another chunk was cut out and a section was welded into place to create the new edge for the headlight surround. the angle was formed after welding using an adjustable spanner to grandually bend the metal over.
to make the recess deeper for the grill it was necessary to remove the lip from the inner edge of the recess, so this was done again the the adjustable spanner and then tidied up with a hammer and dolly.
at this point I was originally going to make a new section to weld between the two cut outs for the over rider as the lower edge is higher than the edges of the bonnet. so I then decided that it would be easier to cut the lower section off and to reweld in 1/2" lower and just make new sections where the over riders were
at this stage I decided that it might be best to check the alignment between the front panel and the bonnet top. Im glad I did as the centre of the front panel and the bonnet top were over an inch out of alignment so I ended up using a shrinker to adjust the fit on the front panel. this started off as a standard shrinker stretcher that I made a new body for
http://www.mig-welding.co.uk/forum/threads/deep-shrinker-stretcher.53923/
and at this stage I thought it might be best to check the alignment of the wings too, so the front end of the herald ended up being assembled ( Ive had the wings and front panel for over 15 years and the bonnet top for over 5 years)
the bottom edge of the front panel was then welded in place and a new section of metal let in where the over riders would have been. not the neatest tig welding in the world but holding together.
unfortunately one side ended up out of alignment due to shrinkage even after tack welding together, so I ended up cutting a couple of slots and having another go.
this shrunk again but not as much even after tack welding, but as I didnt weld the lip to begin with, I was able to hammer the weld to get the alignment back (something I wouldn't have attempted if it was MIG welded).
so next I'll have to make some new sections for the grille surround,think I'll go for this shape. which at my current rate of progress may take up to Christmas. also the cleco clips make it easy to add and remove the front panel and to maintain alignment,but still using vice grips on the wings.
its definately a learning experience I seem to spend longer looking and thinking about how to do things than I do working on it.
or try and make a couple of rear inner wheel arches
and the front panel won.
so this is what the standard front end looks like
with my car I decided that I want to remove the over riders, recess the grill slightly into the bonnet and reshape the grill opening.
as Im still a beginner at this sort of thing I thought I'd post up the trials of doing a simple project....you think its simple as you begin but it soon gets more involved.
so this shows the area to be modified more clearly
so the first thing I did was to cut out a small section to change the profile slightly and reweld it.
the first side I MIG welded,but then spent what seemed like ages grinding the weld back with a power file so for the other side I decided it was time to try some proper work with the TIG welder. Its definately more enjoyable than mig when it goes right, but you do need to work more accurately, and there is much less metal to grind back when finishing with the TIG,expecially with the more detailed areas.
so next another chunk was cut out and a section was welded into place to create the new edge for the headlight surround. the angle was formed after welding using an adjustable spanner to grandually bend the metal over.
to make the recess deeper for the grill it was necessary to remove the lip from the inner edge of the recess, so this was done again the the adjustable spanner and then tidied up with a hammer and dolly.
at this point I was originally going to make a new section to weld between the two cut outs for the over rider as the lower edge is higher than the edges of the bonnet. so I then decided that it would be easier to cut the lower section off and to reweld in 1/2" lower and just make new sections where the over riders were
at this stage I decided that it might be best to check the alignment between the front panel and the bonnet top. Im glad I did as the centre of the front panel and the bonnet top were over an inch out of alignment so I ended up using a shrinker to adjust the fit on the front panel. this started off as a standard shrinker stretcher that I made a new body for
http://www.mig-welding.co.uk/forum/threads/deep-shrinker-stretcher.53923/
and at this stage I thought it might be best to check the alignment of the wings too, so the front end of the herald ended up being assembled ( Ive had the wings and front panel for over 15 years and the bonnet top for over 5 years)
the bottom edge of the front panel was then welded in place and a new section of metal let in where the over riders would have been. not the neatest tig welding in the world but holding together.
unfortunately one side ended up out of alignment due to shrinkage even after tack welding together, so I ended up cutting a couple of slots and having another go.
this shrunk again but not as much even after tack welding, but as I didnt weld the lip to begin with, I was able to hammer the weld to get the alignment back (something I wouldn't have attempted if it was MIG welded).
so next I'll have to make some new sections for the grille surround,think I'll go for this shape. which at my current rate of progress may take up to Christmas. also the cleco clips make it easy to add and remove the front panel and to maintain alignment,but still using vice grips on the wings.
its definately a learning experience I seem to spend longer looking and thinking about how to do things than I do working on it.
