Thanks Everyone,

[redwine300]

Decided to delve a little deeper tonight.
After leaving some measurements behind of the slotted feature in the section to be removed, I carefully cut the section of the outer skin away.
It was as I first thought, a folded seam.
Once that was done, I decided to take out almost the same length of panel below. I stopped a little short so as to give me an edge to weld to.
Next stage will be to grind away any remaining surface rust and treat with inhibitor.
After that I will clean away the surrounding paint work ready for the new metal.

 

[redwine300]

Not much progress tonight,
seemed to spend ages cleaning up the edges and making sure that there was no paint etc'
Did manage to get my first of two repair pieces made up though.
With a bit of luck, I should get it welded in shortly.

 

[redwine300]

After a bit more fettling so as to get the best match possible, I tacked the repair into place. I had to have several attempts before I was really happy though. I guess the car isn't the only thing thats gone rusty.
Still, just like riding a bike, it soon came back to me. (well sort of)
I was determined to get the repair fully welded and dressed back.
All I have to do is trim the lip edge and then I can get some paint on.

 

[smoggyrich]

nice work mate!

 

[Windy Miller]

Fantastic work as usual!

 

[redwine300]

Cheers Guys!!

 

[redwine300]

Not much progress I'm afraid.
Just managed to get some paint on before the relatives decide to visit!!

 

[redwine300]

Well at the risk of becoming monotonous.
Yes you've guessed it, More photo's
Spent a few hours making up the outer skin of the rear lip. With a bit more fine fettling I should be ready to tack into place sometime soon.

If you look closely, you may spot that I have made a fundamental mistake when cutting the angular jointing faces. Fortunately it will be hidden from view and will not be too detrimental.

See if you can spot it.

I may modify existing or worse still, start again from scratch.

 

[redwine300]

Well, virtually ready to tack into place, just need to mark out and cut the square notch on the top edge. Not sure what it is there for, but best put it in.
Not sure as to how I am going to plug weld both sides of the over turned lip as yet, may try and do it all from the outside face.

 

[redwine300]

Another little update.

 

[redwine300]

Once I was completely happy with the fit, I tacked the repair into place.
After tacking, I tackled the plug welds, something that in the past that had troubled me.
I read through some of the advice posted earlier in the post as to how I could improve my technique, and then, after tweaking my set up accordingly, completed the 4 plug welds.
Then it was a matter of gently stitching the 2 ends and grinding flush.

 

[redwine300]

Just thought I would show a, "before and after" photo before I move onto the next bit of tin worm.

 

[redwine300]

Well, bit the bullet and cut this nasty looking piece out.
I was pleasantly surprised to see that it had not attacked the steel below.
Made a start cutting and shaping the repair also, a bit trickier than I first thought.

 

[redwine300]

After what seemed an age, I was finally in a position to tack the repair into place.
I have to say, I do feel particularly proud of this piece due to it's curved profile in two directions.
It gave me a chance to try a bit of shrinking and stretching, and even if I do say so myself, It turned out better than I could of ever hoped.
I even had a go at panel beating the final profile so as to be as good a match as possible.
This gave me a sense of determination to not only fully weld the repair, but to get it ready to paint.
Oh, I did get carried away with the phots also.

 

[smoggyrich]

Excellent work mate. Well done!

 

[redwine300]

Cheers Smoggy,
Praise from someone such as yourself who has posted some excellent work also, makes it even more satisfying and spurs me on even more.

 

[bullet]

out standing work redwine, great to see the start to present with this, not seen much as good as this since my old mans work(panel beater by trade)
i used to love watching him, he loved restoring old classics
atb mark

 

[redwine300]

Thanks Mark, appreciate your compliments.

I still have a few bits still to do, nothing to major, apart from the passenger side rear seat mount section of the floor. (should have done it when I had the interior out really)

I tackled the same thing on the drivers side a little while back so should be fairly straight forward. (never thought I would be saying that when I first set out. lol)

Just need to finish off some much needed decorating so as to placate the wife and then I will be back in the garage. yipeeeeee.
so watch this space!

by the way. HAPPY NEW YEAR EVERYBODY!!

 

[thestig]

just been reading an old thread started by some clown calling himself good welder who is now banned for good reasons, then i look at this thread and in my eyes this is what its all about.
great work red wine and thanks for sharing!
HAPPY NEW YEAR TO ALL OF YOU!!!

 

[selectcase]

What an excellent thread redwine300and thanks for taking the time to take the pics and to post them - I also have to work outside to do some work on my wifes ford transit - its an 03 plate which we just bought and it needs inner and outer sills allready. plus some idiot has sprayed stonechop on to of all the mud and grot underneth - anyway thanks for an inspiring thread- excellent work