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Author Topic: Found Object  (Read 27424 times)
ardiesse
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« Reply #340 on: January 09, 2021, 07:08:58 PM »
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I'm now onto the all-time favourite repair - the cowl/A-pillar bottoms. (\sarcasm)
Things have shifted down a gear or two.  It's just complicated.

I cut away a dodgy repair to the driver's floor, and then a strip of the floor wide enough to get an angle grinder in.  Next to go was a section of the no. 1 body crossmember.  Then it was a case of grinding away the remains of the inner sill, finding the spot welds as I went.  The box-section spacer is not spot-welded on the outside - I put a 7/16 bolt and nut through the hole to hold it in place.  Bit by bit I cleared the inner sill away, until the spacer was left on its own.



While the surgery was ongoing, I turned dressmaker.  I had a paper pattern for the inner sill front from last time, photocopied it, then cut and folded, making adjustments as I went.  When I was happy with the pattern, I transferred it to sheet-metal (and then made a couple more adjustments to fold lines as I went).



I drilled the hole for the subframe bolt, and it wasn't in the right place.  But I remembered good advice from a forum post:  It's only metal.  If you make a mistake, weld it up, grind it flat, and start again.  I welded and re-drilled the hole, and the repair section lined up much better.  Here it is, with another 7/16" bolt holding it in position.



The new section lies flat on the tabs of the box-section.  I have to drill holes for plug-welds, and weld the slots up.  But I have to pay attention to the order of things now.  It's probably a good idea to make the repair sections for the cowl panel before I weld the inner sill repair in place.

This will take some time.  Then I can turn the patterns over and do it all again on the passenger's side.

Rob
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ardiesse
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« Reply #341 on: January 10, 2021, 06:37:24 PM »
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I welded up the slots, and added the lower sill return.  Then I took a template from the box-section, traced it onto the inner sill section, and drilled holes for plug welds, before transferring the box-section over to the inner sill repair piece, and plug-welded it in place.



Rob
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ardiesse
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« Reply #342 on: January 12, 2021, 05:45:01 PM »
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Next, I held the inner sill section in place with self-tappers and a couple of tabs tack-welded on.  Then it was a case of finding spot welds and drilling them out until I freed the outer sill.  With the cowl panel exposed, I then welded up some craters, did a few postage-stamp repairs, and then fabricated the front part of the cowl.  Here it is, more or less welded in place.



Still to be repaired: the part where the subframe bolt goes through; and the bit hidden under the outer sill.

Rob
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ardiesse
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« Reply #343 on: January 13, 2021, 06:18:31 PM »
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So . . . (a needle pulling thread) . . . I can manage about one repair section a day, if the going is good.
This is the right hand cowl bottom, repaired.



That's a relief.  But of course, I get to do it all over again on the passenger's side.

Rob
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Brett027
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« Reply #344 on: January 14, 2021, 01:33:27 PM »
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Looks very neat Rob.

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« Reply #345 on: January 14, 2021, 03:59:21 PM »
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Looks good Rob. I can't tell in the pic, but I hope you put a drain channel at the bottom.
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ardiesse
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« Reply #346 on: January 14, 2021, 04:39:42 PM »
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Haven't yet, but thanks for the reminder.
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Errol62
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« Reply #347 on: January 14, 2021, 11:10:56 PM »
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Yes but if you want to be factory correct you then have to block the drain hole up with a cup of tar Cool Cool


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ardiesse
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« Reply #348 on: January 17, 2021, 04:25:19 PM »
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A few days further on, and the passenger's side inner sill repair has taken shape -



And I managed to get one of the lower cowl section repairs fabricated and welded into place.  While there are fewer rust holes as such on the passenger's side compared with the driver's, I spent a lot of time chasing holes.



The parent metal is paper-thin in places, so I'll be better off chopping out and replacing a larger section.  But first, I have to cut off the front six to eight inches of the outer sill, in such a way that I can repair it and put it back.  I have a (probably naive) hope that I won't have to replace the LH outer sill.

Technology to the rescue.  My nephew has one of these nifty wireless endoscope/borescope thingies, which will be just the thing to explore the inside of the sill so I can get a good idea of how diseased it is internally.

Rob
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ardiesse
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« Reply #349 on: January 23, 2021, 05:59:54 PM »
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Another day, another repair section.

I cut off the front eight inches of the LH outer sill (much guesswork to find the spot welds).

Then I cut out a paper pattern, which I transferred to sheet metal, and gradually formed to shape, trimming bits off as I went.



But I can tell that this is the Australia Day weekend.  How?  Because it's got stinking hot and humid, all in one glorious mix, and I'm working out of doors.

Rob
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ardiesse
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« Reply #350 on: Yesterday at 01:31:55 PM »
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Yep.  It's hot.  But I ventured outside just long enough to weld in the final section -



A voice of caution is telling me to trial-fit the subframe, and only with the subframe in place to weld the inner sill sections into place.

That's not going to be today.

Rob
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« Reply #351 on: Yesterday at 05:23:35 PM »
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My voice of caution would be agreeing with you. When the subframe is lined up the bolts go in easy. If the subframe is out even just a little bit, the bolts won’t go in Tongue

Ken
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