my mk5 cortina estate

[ian f]

What's your welder?

clarke 151en using boc argosheild light on volkzone offer

 

[bill_gj]

clarke 151en using boc argosheild light on volkzone offer

Nice work. It knocks my efforts with a Cebora 130 into a cocked hat. I'm on Volkzone too. Must service that welder.

 

[decca]

Love your work. Thanks for the update. Shame to cut into the rear quarter for that reinforcement. Could it not have been done from the inside? Turned out OK though.

 

[ian f]

Love your work. Thanks for the update. Shame to cut into the rear quarter for that reinforcement. Could it not have been done from the inside? Turned out OK though.

hi, sorry i missed this post. not really possible to get at the area i needed to without removing the inner bracing above the wheelwell and the rear quarter needed replacing where it had stress cracked so two birds with one stone so to speak

 

[steveo3002]

cracking job on making that 1/4 repair panel ...some during /how to pics would be good too , id like to be able to make something like that

 

[mechman]

Whatever happened to this project it seemed to be going so well and good skill too

 

[Freddy0309]

Missed this thread somehow and although the car doesn't interest me I am really in awe of the fabrication skills

 

[ian f]

hi everybody, only just seen these reply's sorry for not keeping this thread up to date plenty of pics taken and uploaded on facebook but always too interested in other peoples projects on herethe car has had all the welding finished. stripped to bare metal (starchem synstrip) , lechler epoxied and now i'm in the process of skim coating with filler to get everything straight

 

[ian f]

will try and keep more updated

 

[ian f]

hi. everything on this side blocked down

then re epoxied (lechler 29107)

 

[ian f]

i thought i'd done welding but this piece kept bugging me i repaired the boot floor about 18 years ago making the two strengthening ribs on the right over an open vice. while still solid and being painted in stonechip so not really noticeable i thought i'd have another go. worst case it gets extra coats of stonechip!

so blank cut out and start tapping

second rib

needs a bit more time spending on it. i know it wont be perfect but looks better than before and with a light coat of gravitex should blend in quite well

 

[mechman]

Crackin job, old Henry would be proud of ya.

 

[ian f]

just a quick update the panel is now welded in (butt welds) and now ready for grinding and blending in

 

[mechman]

Ian f
Can you bless us with a foto of the tool you use for those swages.

 

[ian f]

hi mechman. sorry i didn't reply i've been struggling with sciatica (still am) i just use an old file as a former which is drilled and tapped to bolt it to my "tony bmw" folder

then using a wide chisel with the edge rounded and a lump hammer

then second edge

 

[ian f]

then when you want to do the ends

flat bar

smack

to round off the corners i just move the bar round while tapping

the end result. this is just a quick demo obviously the more time you spend on it the better

 

[mechman]

Excellent, to me anyway, I love innovation and stuff like that.

 

[WorkshopChris]

Im always on the lookout for old or cheap bolster chisels, so useful i have them ground from a very slim sharp taper ideal for separating panels between spot welds, through to ones modified up to about 8mm radius.

 

[onlyme]

Absolutely cracking work there Ian. Envious of your skills.

 

[brightspark]

Im always on the lookout for old or cheap bolster chisels, so useful i have them ground from a very slim sharp taper ideal for separating panels between spot welds, through to ones modified up to about 8mm radius.

I have about 9 of them all second hand and British make very thin for mainly taking floorboards up paid 2,50 each for them from auto jumbles