Awkward shape suggestions needed

[RaceDiagnostics]

Ok I have cut out the rot, for the repair patch, do I

1) try to cut out a shape like this

2) do it in two sections

3) make the hole bigger and more regular

4) other.....

 

[the snooper]

I would cut out the 2 corners sticking inwards and just make them straight and it would be slightly less welding

 

[Burdekin]

One would look neater but two is no big deal.

Make it with cardboard first and you'll get the sizing and know how to bend and fit the repair easier.

 

[Landynut]

You could also cut shape with jigsaw if you have one. It will do it in seconds

 

[octo0072000]

I wold cut out the 2 corners sticking inwards and just make them straight and it would be slightly less welding

plus 1

 

[colnerov]

I wold cut out the 2 corners sticking inwards and just make them straight and it would be slightly less welding

Plus 2. I would even be tempted to take it out to the panel overlap on the right and duplicate it.

Colin

 

[Seadog]

I wold cut out the 2 corners sticking inwards and just make them straight and it would be slightly less welding

Are you sure? If you're cutting out two rectangular sections you'll still be welding the same length of edge. But I agree it's the easiest way forward.

 

[the snooper]

Are you sure? If you're cutting out two rectangular sections you'll still be welding the same length of edge. But I agree it's the easiest way forward.

yeah cut off those 2 bits and its less weld

 

[RaceDiagnostics]

Thanks all.

Snoop, I thought you meant the same as Seadog, so here is what I did.

Card template.

Bent it bit by bit in the vice to get the shape.

Tacked on a bolt to help position.

Fettled till it fitted.

 

[Burdekin]

Nicely done.

 

[the snooper]

Thanks all.

Snoop, I thought you meant the same as Seadog, so here is what I did.

Card template.

Bent it bit by bit in the vice to get the shape.

Tacked on a bolt to help position.

Fettled till it fitted.

swings and roundabouts looks neat and good fit

 

[RaceDiagnostics]

This car is a pain in the ass....for anyone tempted, just don't do it.

Inside the offside wing under the headlight.

 

[Bill Edwards]

Yep, restoring old vehicles...

 

[mechman]

What breed of vehicle are we looking at?.

 

[RaceDiagnostics]

2002 XK8 I bought for the wife about 4 years ago. It stared off as a fairy tail......

Here are a few of the horrors I have found on what was a 10 year old car.

Lots of sheared bolts going into captive inaccessible nuts. Some one had put a nut in here with RTV.

These sheared bolts hold on a cross brace.

Same at the other side.

Solved like this.

Hidden by the front subframe.

Charcoal canister bracket had disintegrated.

Rear wings.

Had to do both.

Front wings.

Had to do both.

Wing mirror brackets?

Of course.

Or how about a disintegrated bumper bar support.

Disintegrating window trim.

How about a disintegrating rear chassis.

Hole in your cat, no aftermarkets available OEM £1700. Weld it up.

Rust round the windscreen.

Electric Heater pump brush replacement, 8 hour job! or £1000 if you want a franchised dealer to do it.

And not to forget the last job, rusted out seatbelt anchors.

Rusted out window regulator.

This is just the half of it, what a horror story!

 

[octo0072000]

has it been a seaside car parked on or near the sea i bought a escort estate from blackpool even though it looked ok underneath was a similar nightmare patches welded on top of patches etc

 

[slim_boy_fat]

2002 XK8 I bought for the wife about 4 years ago. It stared off as a fairy tail......

Come on, 'fess up - you really bought it as a project for yourself, and score Brownie Points at the same time.

 

[Sarto]

What is a Brownie Point?
On a serious side, nice job, and lot of patience.

 

[slim_boy_fat]

What is a Brownie Point?

This describes the concept in its basic form - but often used to gain favour with one's wife/husband/partner

http://www.urbandictionary.com/define.php?term=brownie points&utm_source=search-action

 

[RaceDiagnostics]

The last thing I needed was another project car, fessing up... but did think it would be cool to knock about in.

It was bought as a daily driver back in 2012 with ~100k on the clock, Kim then used it as a daily driver for three years clocking up another 30k miles or so. It has mainly been used as a weekend car for the last year since I changed jobs and we now car share.

I really didn't expect it to have so many problems and really wish I'd never bought it. After this current round of repairs it's going to turn into a summer/dry weather only car, no point selling as its not worth much... and its almost sorted now.