Meet Ted

[Panky]

The welding to the body is pretty much finished on that side so I started repairing the rear wing

I killed another angle grinder, lets see how long this one lasts. And I finally got to the welding place to get more gas and sheet metal.

The flange (steady Jim) was a bit frilly but the rest of the wing was good and solid (surprise surprise )

Some new metal welded in

Quite happy with that, nothing a bit more fettling won't fix

 

[jimberlake]

I’m saying nothing

 

[PaulJL]

I've been through so many grinders.. the latest one has outlasted the rest by at least twice. It's a 110v one with soft start so that might be helping

 

[Gladys Crew]

looking great Mr P keep up the good work, Hopefully I will be able to pop over one day soon to watch a master at work.

 

[jimberlake]

Look good welds those Panky - wish I could get close to that, i need to invest in a proper welder rather than cheap rubbish

 

[Panky]

Mines not an expensive one, it's a Migmate 130 turbo that I've had for nearly 20 years. I have modified it with a euro torch and the Chinese toilet extractor fan and it works pretty well, next mod is an up-rated wire feed at some point. I did get a very cheap Sealy and it was OK for a while, but I sort of killed it I then dug out the Migmate and got it going again.

 

[jimberlake]

Mines gasless, need a gas one to do anything reasonable I think.

 

[jimberlake]

Maybe it’s just me

 

[Panky]

It's more difficult to get a decent weld with gasless. I use pub gas (CO2) and it gives reasonable results and at only £15 for a re-fill it's cheap too

 

[bazzateer]

Mines not an expensive one, it's a Migmate 130 turbo that I've had for nearly 20 years. I have modified it with a euro torch and the Chinese toilet extractor fan and it works pretty well, next mod is an up-rated wire feed at some point. I did get a very cheap Sealy and it was OK for a while, but I sort of killed it I then dug out the Migmate and got it going again.

How does an extractor fan for a Chinese toilet differ from one for a UK toilet?

 

[PaulJL]

It's more difficult to get a decent weld with gasless. I use pub gas (CO2) and it gives reasonable results and at only £15 for a re-fill it's cheap too

Same here. Gas less is great for thicker metal but no good for thin stuff.

 

[jimberlake]

I blew holes in test welds for the front even lowest setting so got someone in to do it

 

[renaultvation]

Can your gasless welder be converted to gas? I have a Clarke welder which can be used for either. I tried gasless, but it wasn't very user friendly and created lots of spatter. Now I use it with Hobbyweld gas and it is like a different machine.

 

[jimberlake]

No it’s can’t, waste of money really. I’ll be looking at some like that in future. Will need another car first as hoping this one doesn’t need any now for years

 

[nickclubman]

In the last week, my grinder has given up along with my powerfile, feeling your pain.
great work though.

 

[Panky]

A bit of BOTG time spent repairing Ted's front wing, Most of it was OK so seemed a shame to replace (and save over £200 )

The trailing edge had rust holes all the way down

From the inside

Didn't take much to remove the stiffener

Both edges of the stiffener as well as the wing edge needed repair

The rest of the inside was stripped and treated with Deox gel to get rid of surface rust and a little light pitting near the head lamp end

And a dash of zinc

I left it there and will finish it off during paint prep.

Next up is the drivers side door bottom - oh joy

A Morris Traveller door bottom kit

 

[Panky]

The last couple of weeks has mainly been spent of rebuilding Teds door

That's a surprise

I decided to buy a bottom skin repair panel as making one was a bit complicated but the fit wasn't that good

The straight end was easy to fix but the curved trailing edge needed a 1/4" strip letting in

Luckily I've got the latest version of CAD

Transferred to metal

The bottom section was later placed inside the other repair sections in an attempt to replicate the original. Here screwed to the outside just to get the temporary fixings in place.

Al welded in place

A skim of filler should cover the seam, and a repair to the leading edge of the door will see it done

 

[S0updragon]

Blimey. A lot of work. Cracking job

 

[Panky]

Fitted the wing and door to see how they lined up
Front wasn't too bad but the door was catching where the wing edged was sitting back a bit

So out came special tool Panky 001 , laminate floor edge tamper
A couple of taps with a hammer fixed the problem

The back edge was a different matter

A piece of 1/8th welding rod to the rescue

That's a bit better, I can work with that and get it perfect

 

[Panky]

Next up was the top of the door opening and gutter.
It's made up of a couple of sections so lots of spot weld drilling

What's left of the gutter

New section in place using tech screws for now

Plug welded in place

Then I made a jig to form the gutter edge
A 4" round nail welded to a piece of angle iron

Curve formed in short lengths

Until the full length was done

Offered up

Holes punched for plug welds and given a splash of weld through ready to go on tomorrow

I enjoyed that little bit of fettling