Thanks Everyone,

[redwine300]

Chickenjohn, Thanks again. Having read your recent post, as you say, it makes perfect sense to steer away from continuous welds and stick to what has served me well so far.

Anto, Thanks for your comments also, very much appreciated, As for finding the time, I know what you mean. I look at it like this, so long as I do something each week, Even if it is only a little bit, it all brings that completion day just that little bit nearer.

I was really lucky with this repair, nearly cut it short but just managed to save it. Once I had the basic shape and size, it was a couple of hours tweaking the edges until it laid flush at all the mating edges.
Once I had tacked it into place at several points, I moved onto the inner plug welds. I started at the top edge clamping the repair closely to the mating part as I went. Still struggle with hitting the set up first time mind.
Thankfully, time allowed me to almost finish up welding into place, just the upturned lip at the front edge to do. Better not c*$k that up.

 

[Sphinx]

Cracking mate!
I...well...can't be arsed finding the page with the interior picture but is the car a manual?

 

[redwine300]

Thanks Sphinx, Yes it is
Couldn't resist the picture one more time

 

[Sphinx]

This may sound mad but it just looks like such a nice place to be. Soft and comfortable looking, even without seats lol

 

[tux]

Definitely mangoes!

 

[katbloke]

I wish i had taken more notice and not tried continuous as i feel i did more harm than good, cant wait for it to warm up a bit and get some time off work to have another go to correct what i started.

Great work as ever

 

[redwine300]

Not much in the way of welding today I'm afraid,Still, managed to finish off the inner lip to the lower wheel arch though. looks like it will be mostly cutting metal out tomorrow as well.
Spent a few hours flatting off my recent attempts at thin metal welding and smoothed out with filler ready for primmer.
Katbloke, I know what you mean with regards to seam welding, I nearly went the same way but Chickenjohn steered me away just in time. I hope that it will not take you to much work to rectify your problems, and hopefully you will be able to move forward with that knowledge.
Are you running a post of your progress to date?

 

[Sphinx]

Looking good, are you going to take the back box off and do that other panel from behind?

 

[redwine300]

Cheers Sphinx,
As for your question, I have decided to tackle it from the front. There are 3 reasons for my decision,
(1) I needed to know the integrity of the front panel.
(2) Thought it might be good practise with regards to cutting away good material with the intention of welding it back from whence it came.
(3) I am putting off any major strip down until I have to! (probably the real reason)
That said, Once I had decided on where I was going cut, I marked up the area and made the 2 saw cuts first, this then left me with the drilling of the spot welds and allowed me to gently remove the good section without to much damage, (should tidy up nicely and looks OK to put back later)
After some paint stripper and an hour or so grinding back the rust it did not look as bad as first feared, (that makes a change)
After a couple of coats of rust treatment on the minor areas, I marked out the area to be cut out. Tried to make the a fairly basic shape so as to make the replacement section easier to match up.
I ran out of time at that point, I was hoping to get the repair panel tacked in at least, I will have to wait until next week I suppose.

 

[Sphinx]

What size cutting disc did you use to remove that section of outer panel? I've always wondered about how this could be done, ie welding a piece back in, as the gap left from the cut could be tricky to bridge on thin metal.

Getting there though! I'm sure soon enough you'll have a nice solid car ready for paint

 

[katbloke]

My thread died a bit after my hole blowing session, bit disheartened so have left it till warmer times. Sorn'd now and not insured so no rush tbh especially at 130 a litre

 

[redwine300]

Hi Sphinx,
In this instance i have used a junior hacksaw, it has left me with approximately 0.5mm gap which I have not tackled before. I feel fairly confident that I will be able to bridge the gap, so long as I am cautious about the weld shrinking and pulling the replacement out of position. It will need a few initial strategically placed tacks to start with.
In a strange way i am looking forward to attempting it for the first time and will post all that I encounter, good or bad.
Bring on the weekend

 

[redwine300]

By the way Katbloke, Try not to get to disheartened, it will be worth it in the end. (well that's what I keep telling myself) I know what you mean about fuel costs, I dread to think how much it will cost to fill the Nissan. (12 gallon tank i believe) and only 20 to the gallon
dig deep mate.

 

[Sphinx]

0.5mm is much better than I thought, I had visions of at least a 1mm gap all the way around causing problems. I'm sure you'll have no trouble putting it back.

As for fuel costs, try running an old 2.5 straight 6 with dodgey vanos when you're 'between jobs' (posh for jobless)...not a twin turbo V6 but painful none the less

 

[redwine300]

Fortunately the weather stayed dry today, albeit a bit windy. So i was able to get quite a bit done, just fell short of primer due to bad light.
Once i was happy with the fit, i placed some initial tacks allowing me to keep the repair in place and flush in all the right areas. I have started making my initial tacks as small as possible to begin with, this way I am able to tweak the position a little easier should anything move.
once tacked i managed to fully weld into place despite the awkward angle and grind reasonably flush prior to primer.
Now came the easy bit (NOT!) this is where I needed to weld back an original good section that i had previously removed for better access.
Not only is the parent metal slightly thinner than the repair, I now have 2 pieces of parent metal and a 0.5mm gap to overcome. I really had to go easy and cautiously so as to not blow through.
I left all my settings alone and adopted a very short burst of weld technique with a quicker torch speed. I could see the weld pool form almost instantly.
Still, got there in the end with only a few holes to over weld, lets hope the vent duct still fits.

 

[keith19]

Another nice careful job, Redwine. And putting parent metal back is always a challenge, a challenge you have met here very successfully. Well done!

 

[redwine300]

Thanks Keith19,
Not much in the way of welding today though I'm afraid,
Family member dropped by,
Oh,could you just weld this exhaust bracket? Oh and this bracket? Before I new it, the day had gone!
Still, managed to acid etch and white primmer the last bit of the lower rear arch repair. I suppose that's something.
Will just have to hope the weather holds off tomorrow.

 

[katbloke]

 

[Chickenjohn]

Really nice neat work again, Redwine! I think you should paint the car yourself as well. That level of attention to detail will result in a potential concours contender at the Nissan owners rally!

 

[Sphinx]