Pigeon_Droppings2
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Pigeon_Droppings2
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Where the template shape is complex I tend to use masking tape to make up the template...it stays in place on its own which is quite useful. I draw the template on the tape, peal it off and then stick it on the sheet metal and cut it out. For flat templates I tend to use card but I think tape seems to work better for curves...you have to allow a little extra metal for making the curves of course.
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Pigeon_Droppings2
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Pigeon_Droppings2
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I decided to stick with the original nissan design in this area but I continuously welded in the repair to prevent moisture getting into the join.
I decided to extend the vertical filler piece...not sure why exactly other than thinking it would look nicer....the filler piece also has a slight curve to it...that shrinker really does come in handy for this sort of tweaking.
The top of the inner arch isn't welded because this will eventually be joined to new metal when the arch gets done so I'm leaving it lose to allow some tweaking to match the outer arch when it gets fitted.
I flattened the welds and then threw some etch primer over the new stuff to keep the rust off.
The bottom edge will get cut and finished off when the outer sill is fitted...for the moment I just left it a bit long so I have enough extra to turn a lip on the bottom.
I decided to extend the vertical filler piece...not sure why exactly other than thinking it would look nicer....the filler piece also has a slight curve to it...that shrinker really does come in handy for this sort of tweaking.
The top of the inner arch isn't welded because this will eventually be joined to new metal when the arch gets done so I'm leaving it lose to allow some tweaking to match the outer arch when it gets fitted.
I flattened the welds and then threw some etch primer over the new stuff to keep the rust off.
The bottom edge will get cut and finished off when the outer sill is fitted...for the moment I just left it a bit long so I have enough extra to turn a lip on the bottom.
Pigeon_Droppings2
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Pigeon_Droppings2
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At the rear I connected the inner arch repair panel to that triangular stiffener.. This was the piece I put into the inner arch in the earlier pic...it curves into the sill and gets attached to the triangular stiffener.
On the sill reinforcer in the bottom pic I left a tab on it and connected the reinforcer into the inner arch...this felt right to be even though I'm not sure that this is original!
The gap at the bottom of the reinforcer has been left to allow for drainage. I think this is pretty much as far as I can get on the rear part of the sill as I need to work out how the arch repair will join into the outer sill.
Not sure what my next job is going to be....it's still a very long list of course....just not sure what to tackle next. I'm thinking of just getting all the horrible stuff out of the way so I might work on the drivers side sill next.
The drivers sill is going to be a repeat of the passenger sill....if you guys still want to see pics of the repair just let me know...otherwise I'll just take a few here and there. Don't want to drown everyone in pics just for the sake of it.
On the sill reinforcer in the bottom pic I left a tab on it and connected the reinforcer into the inner arch...this felt right to be even though I'm not sure that this is original!
The gap at the bottom of the reinforcer has been left to allow for drainage. I think this is pretty much as far as I can get on the rear part of the sill as I need to work out how the arch repair will join into the outer sill.
Not sure what my next job is going to be....it's still a very long list of course....just not sure what to tackle next. I'm thinking of just getting all the horrible stuff out of the way so I might work on the drivers side sill next.
The drivers sill is going to be a repeat of the passenger sill....if you guys still want to see pics of the repair just let me know...otherwise I'll just take a few here and there. Don't want to drown everyone in pics just for the sake of it.
Pigeon_Droppings2
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Got the grinder out ready to start cutting the drivers side sill....then had a moment. The thinking goes....if I cut it all up how will I replicate the sill closer on the passenger side when I don't have one to copy...I have a second figaro but I don't really want to start stripping it down! So the new plan is to make the sill end before I start cutting. This is my second attempt...while it looks like the dogs dinner it is kind of getting the basic shape I need so I'm going to fiddle around with it to see where it gets me. I used the stretcher to get the main lip done and then just hacked about with it. The nissan original was several pieces with spot welds....I'm going to try to butt weld everything to reduce the chances of water creeping in.
jpmillermatic
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thats a complicated piece!...kudos on tackling that in one go....
JP
JP
Pigeon_Droppings2
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Cheers JP...yea it's either brave or a bit stupid....I figured it was worth a shot plus it's nice to do a little metal bashing now and again.
Pigeon_Droppings2
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So the problem with doing the sill end is you need the sill to work to. My sill "almost fits"...I think part of the problem is there are 2 patches on the sill from previous repairs...I figured get rid of those and I'd need a lot less filler!
Was hoping to just pull the patch off but it was rusted underneath so ended up cutting it out and replacing with new steel.
Was hoping to just pull the patch off but it was rusted underneath so ended up cutting it out and replacing with new steel.
Pigeon_Droppings2
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Patch #2 was alot more involved. I turns out the sill actually joins the rear quarter at this point...it then runs behind the rear quarter and forms a reinforcer for the rear arch....gulp!
One step at a time and eventually I had the outer part replaced...I had to run a first patch behind the rear quarter so it also repaired the reinforcer. Then stuck a bunch of weld thru primer on there before putting the second patch on which forms the outer sill.
One step at a time and eventually I had the outer part replaced...I had to run a first patch behind the rear quarter so it also repaired the reinforcer. Then stuck a bunch of weld thru primer on there before putting the second patch on which forms the outer sill.
Pigeon_Droppings2
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Next job was to reconstruct the sill reinforcer....I think it came out quite well.
So to be clear in this section we have:
1. Floor flange
2. Inner sill
3. Inner sill reinforcer
4. Outer reinforcement (the square bit)
5. Additional reinforcer
6. Outer sill
Geez thats a lot of layers in such a tiny car!
4 & 5 will be tied into the inner arch before I fit the outer sill panel.
So to be clear in this section we have:
1. Floor flange
2. Inner sill
3. Inner sill reinforcer
4. Outer reinforcement (the square bit)
5. Additional reinforcer
6. Outer sill
Geez thats a lot of layers in such a tiny car!
4 & 5 will be tied into the inner arch before I fit the outer sill panel.
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Pigeon_Droppings2
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Then finally it was on to the sill end piece....I think I have something that I can work with...still needs some tweaking but it's getting there.
I had a bit of a nightmare with the outer sill...it just wasn't working out...in the end I had to hit it with a hammer. It's now much closer but will need some tweaks.
I had a bit of a nightmare with the outer sill...it just wasn't working out...in the end I had to hit it with a hammer. It's now much closer but will need some tweaks.
Pigeon_Droppings2
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Pigeon_Droppings2
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And the award for the most stupid location for a roof drain tube goes to....
That little tube goes straight into the inner sill...there was even a little rot hole at the end of the tube. I think this little "feature" pretty much guarantees that any Figaro which gets driven in the wet is going to have a similar issue. Just imagine salt spray going down that little tube and being delivered into the sills!
The rust shape even matches the level of the little tube....just bonkers! I'm going to do something to route the tube out of the car....either down and out the bottom or maybe out the front into the arch area and then down. All I know is that it can't go back in where it currently lives!!
That little tube goes straight into the inner sill...there was even a little rot hole at the end of the tube. I think this little "feature" pretty much guarantees that any Figaro which gets driven in the wet is going to have a similar issue. Just imagine salt spray going down that little tube and being delivered into the sills!
The rust shape even matches the level of the little tube....just bonkers! I'm going to do something to route the tube out of the car....either down and out the bottom or maybe out the front into the arch area and then down. All I know is that it can't go back in where it currently lives!!
Pigeon_Droppings2
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Bit more progress....managed to get the repair of the outrigger and the under plate for part of the floor done. Quite fiddly stuff but needs doing as I want a standard look for the floor. Space is of course very limited in there + I have to protect the wiring and fuse boxes with blankets so lots of fun it isn't!!
Just checked the welding gas and it's almost gone....I know I did quite a bit of welding but I bought a big bottle (20L) so a bit surprised it's empty already. I'm hoping I can get the floor repair done before it runs out!
Just checked the welding gas and it's almost gone....I know I did quite a bit of welding but I bought a big bottle (20L) so a bit surprised it's empty already. I'm hoping I can get the floor repair done before it runs out!
Pigeon_Droppings2
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Cheers rtcosic....certainly getting a lot more handy with the grinder...I worked out that if I cut the floor, the inner sill and the outer sill then I can pretty much pull the lot out in one piece. That has made things much quicker than disassembling the layers one at a time which is how I was doing the first side.
Funny I had Blinky in my mind this afternoon too...their work is just crazy crazy special I think. Did you see that fan housing....I mean wow!
The Figaro will be a good driver rather than a show car...to get higher quality I think I'd need the car rotisserie for sure. With the brace in the way I was basically welding today stretched half way across the brace with my feet outside the car, head inside, one hand holding onto the car for stability and the other waving the torch around like Luke Skywalker...not idea at all.
Would be a great conversion to stick a GT4 engine in a Figaro....to be honest I was toying with the idea of an electric conversion for the second car...
Funny I had Blinky in my mind this afternoon too...their work is just crazy crazy special I think. Did you see that fan housing....I mean wow!
The Figaro will be a good driver rather than a show car...to get higher quality I think I'd need the car rotisserie for sure. With the brace in the way I was basically welding today stretched half way across the brace with my feet outside the car, head inside, one hand holding onto the car for stability and the other waving the torch around like Luke Skywalker...not idea at all.
Would be a great conversion to stick a GT4 engine in a Figaro....to be honest I was toying with the idea of an electric conversion for the second car...
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rtcosic
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It's smaller and lighter than an MX-5 I'm sure. When No 2 son and I did the sills on his MkI we struggled working upside down on axle stands.
When it came time to do his MkII No 1 son made a pair of triangular supports c. 1 metre high. Engine, box, rear axle assembly etc removed. Set one sill on the ground.
No 2 and I lifted the bare shell and No1 inserted the two 'props. Left the shell at c. 45 deg angle. Props were tacked to the shell and additional bracing tacked on. Not exactly upside down as on a rotisserie but the working area was at waist height and 'upside down' became 'at an angle'. Vastly easier!
Subsequently I bought an engine crane and it would be a one man job with that.
