As soon as I seen it I was like that's a great idea!! Deffenitey stealing that one.
- Thread starter Myles1970
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Myles1970
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I've been putting this one off: some old spot welds on the bulkhead which had rusted through... Halfway through welding in the patch I realized that I hadn't primered it 
...so off again... I've decided to cut the flange off the inner wing where it mates to it as it way really crusty, thin and cracked (if you look close)
...so off again... I've decided to cut the flange off the inner wing where it mates to it as it way really crusty, thin and cracked (if you look close)
Myles1970
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... complete with old plug welds on the plate above it.... it's quite a complex joint up there, with about 5 different pieces joined, previous repairs and plug-welds...I could be approaching the limits of my skillset. Rust converter and preserving treatment may be the way to go...
Myles1970
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Fabricating the repair section...
I suppose I could have made it from one piece, following the complex contours of the inner wing and cut reliefs to allow me to create the flange, but instead I copied the flange using some tape and moulded the inner wing section to match it. As there's a square 'lump' near the bottom, and it's solid I just re-used it:
In the above image you can see where I scribed the cut line for the flange.. using these aviation shears that are proving ideal for trimming patches
...Now, the fun part will be getting it to fit
I suppose I could have made it from one piece, following the complex contours of the inner wing and cut reliefs to allow me to create the flange, but instead I copied the flange using some tape and moulded the inner wing section to match it. As there's a square 'lump' near the bottom, and it's solid I just re-used it:
In the above image you can see where I scribed the cut line for the flange.. using these aviation shears that are proving ideal for trimming patches
...Now, the fun part will be getting it to fit
I'd say if you did that out of one piece it would have been a ball ache I'd say.
In terms of cutting using the shears I really not like them for cutting pannel either I picked up a cutting head for my Dremel and I have to say it's a great job for small cuts and awkward shapes. I seen there's even an attachment to give it a swan neck so if you're getting up onto awkward spaces you don't even need to be able to fit the body in there.
Do you have a propper folder Myles?
In terms of cutting using the shears I really not like them for cutting pannel either I picked up a cutting head for my Dremel and I have to say it's a great job for small cuts and awkward shapes. I seen there's even an attachment to give it a swan neck so if you're getting up onto awkward spaces you don't even need to be able to fit the body in there.
Do you have a propper folder Myles?
Myles1970
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That sounds ideal. I've been using an air saw for cutting out rusty sections, and the shears for the repair sections. I then fine tune with either a flap disc or 10mm belt sander
No...(not yet)...just an off cut of H- beam and a bat or a hammer
Myles1970
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Thanks...I'm just learning as I go along, but if I can preserve the size and shape (angles included) of the pieces I remove and try getting the repair as close as possible, normally a little bit of persuasion does the rest when welding it in.
I would love to get my hands on a stretcher/shrinker, bead roller, press brake, bench shear, english wheel....(I could go on), but as this is a hobby and I have other financial commitments ...not to mention a couple of grands worth of spares still to get for this, they'll have to wait
Dcal
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I've all those things, except the press brake and I made a tool that worked in my big press that did the job I needed. (bending 6mm stainless)
I've now got the bits to make a press brake out of my old press, but haven’t got the time yet.
All the stuff I either got cheap and modified or just made from scratch.
It wasn’t expensive in money (it certainly was in my time) but it helps if you like making tools.
Having said that, it's really good practice to shape metal using hand tools, it gives you a great understanding of how the metal wants and needs to move to get the results you want.
With hand tools you do the least work required to get the result, with power tools you can just batter the metal into submission.
Keep up the good work.
Myles1970
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...and on with the bulkhead patch,
Welded using 0.8 wire ... The material is 1.2mm:
It actually went on ok. I got a couple of spots tacked on flush, then with the aid of a small screwdriver I got a few more.... Bit of persuasion from a hammer to get the ridge at the bottom to meet and done!
It took me about 3hours this evening after work to weld that patch in...and grind, this is the same patch as viewed from the wheel well:
I didn't bother so much with the interior side as it will be behind the dashboard, unseen.
Next will be the section with the flange that is spot welded to this and will be butt welded to the apron. It's 0.8mm so I'll be going back to 0.6 wire. I'm considering using the tig for the spot welds....
Welded using 0.8 wire ... The material is 1.2mm:
It actually went on ok. I got a couple of spots tacked on flush, then with the aid of a small screwdriver I got a few more.... Bit of persuasion from a hammer to get the ridge at the bottom to meet and done!
It took me about 3hours this evening after work to weld that patch in...and grind, this is the same patch as viewed from the wheel well:
I didn't bother so much with the interior side as it will be behind the dashboard, unseen.
Next will be the section with the flange that is spot welded to this and will be butt welded to the apron. It's 0.8mm so I'll be going back to 0.6 wire. I'm considering using the tig for the spot welds....
Myles1970
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I'm not sure it's entirely necessary, but if you look at the bead on the second pic on post #153, that was after a fair bit of grinding. That's fine for strength where it can't be seen.... 0.6 means less grinding, for me anyway...
...I know, inspirational stuff!!
I bought from Buy Metal Online.... Delivered via parcel wizard, that was before b****t tho...
)
Myles1970
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So now I have the bulk of the welding on the front clip done, getting it ready for the epoxy sealer/primer
....that's one side bear after wiping off with thinners... and the wheel well:
I just have to prep the nearside; it's rust free, just needs the factory stone chipping removed and keyed for adhesion..... Pressure is on as this side is naked
....that's one side bear after wiping off with thinners... and the wheel well:
I just have to prep the nearside; it's rust free, just needs the factory stone chipping removed and keyed for adhesion..... Pressure is on as this side is naked
jpmillermatic
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very nice and careful work there!
JP
JP
Ctreanor13
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That's some amount of work in there lad, was showing one of the fabricators at work who has built a fair few rally cars etc including a full show car restoration on a 1978 Celica with his friend and his words were "Christ where would you even start there". Where in Monaghan are you out of curiosity?
Myles1970
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It keeps me busy alright, I'm in blayney... Had a ta22 celica years ago that I bought as an unfinished project:
... that was before the prices went through the roof. Wasn't show quality but it was good craic
.I'm guessing from your username you're not a million miles away?
