should of bought a commer!
Commer Dandy by Dandy Caravans
The Colonel Mustard
Commer Dandy by Dandy Caravans
The Colonel Mustard
Vive le rust porn
- Thread starter renaultvation
- Start date
renaultvation
Well-Known Member
It's been a long time, but there is a little progess on reconstruction. Work has stopped on the A pillar as there is a dirty great Moto Guzzi occupying the end of the workshop where I was doing the fabrication (I don't want stray sparks near it). 
However, I am able to start the reconstruction of the inner wing and front of the sill.
I am trying to repair the remains of the original, rather than cut it all out and fabricate new. The reason for this, is to maintain critical dimensions and add strength to parts of the structure before I remove other elements.
Progress so far:
New metal stitched in to replace gaping holes. Flanges on parts of the bulkhead behind the wing had to be replaced beforehand.
Section of outer sill cut away to reveal remains of mid sill membrane (this forward section will be replaced).
New section of outer sill already made, but will not be installed until all other repairs have been carried out on this corner. I made it first while I had something to measure and fit it against.
When it comes to welding the sill, I intend to drill some holes parallel to the join and plug weld an overlapping flange behind which I can plug weld the new section to, then seam weld the join. I hope this makes sense.
'I intend to live forever - so far, so good'
However, I am able to start the reconstruction of the inner wing and front of the sill. I am trying to repair the remains of the original, rather than cut it all out and fabricate new. The reason for this, is to maintain critical dimensions and add strength to parts of the structure before I remove other elements.
Progress so far:
New metal stitched in to replace gaping holes. Flanges on parts of the bulkhead behind the wing had to be replaced beforehand.
Section of outer sill cut away to reveal remains of mid sill membrane (this forward section will be replaced).
New section of outer sill already made, but will not be installed until all other repairs have been carried out on this corner. I made it first while I had something to measure and fit it against.
When it comes to welding the sill, I intend to drill some holes parallel to the join and plug weld an overlapping flange behind which I can plug weld the new section to, then seam weld the join. I hope this makes sense.
'I intend to live forever - so far, so good'
commeracer
Well-Known Member
Keep going Chris, there,s a finish in there somewhere
"You,re only supposed to blow the bloody SLIDING doors off"
"You,re only supposed to blow the bloody SLIDING doors off"
renaultvation
Well-Known Member
A bit more progress today:
Having cut away the remains of the rotten section, I made an inner reinforcing membrane for added strength and painted everything which will be hidden with red oxide, leaving just those bits to be welded.
Top section fitted
Bottom section
That's it for now as Liz is off tomorrow and I am to take her out to lunch, then on Friday it's off to that London for a couple of days as tourists.
'I intend to live forever - so far, so good'
Having cut away the remains of the rotten section, I made an inner reinforcing membrane for added strength and painted everything which will be hidden with red oxide, leaving just those bits to be welded.
Top section fitted
Bottom section
That's it for now as Liz is off tomorrow and I am to take her out to lunch, then on Friday it's off to that London for a couple of days as tourists.
'I intend to live forever - so far, so good'
sweedspeed
Member
Looking good !
Keep at it, its always nice welding bits back in rather than cutting out rust.
www.facebook.com/MSAAutobodies
Keep at it, its always nice welding bits back in rather than cutting out rust.
www.facebook.com/MSAAutobodies
renaultvation
Well-Known Member
Not a lot of progress to report since my return from that London. I thought I might be able to salvage and repair the inner strengthening membrane from the A pillar and repair it, but it was too far gone. However, there is enough of it that I should be able to take the critical dimensions and make a copy.
Good news, after further fettling, I clamped the new outer A pillar panel in place and tried the front wing in position. The two went together beautifully, which is just as well as the wing bolts to the pillar in two places. I haven't formed the holes for the door hinges yet, so cannot try the door for fit.
'I intend to live forever - so far, so good'
Good news, after further fettling, I clamped the new outer A pillar panel in place and tried the front wing in position. The two went together beautifully, which is just as well as the wing bolts to the pillar in two places. I haven't formed the holes for the door hinges yet, so cannot try the door for fit.
'I intend to live forever - so far, so good'
renaultvation
Well-Known Member
After much inactivity, I have finally got back to my project. Constructing the A pillar from scratch was not easy, particularly since I wanted to recreate the profile of the original. Using my rusty spares car for reference I eventually got there.
First job was to fit the inner stiffening section, then I tacked the outer panel in place. Having tacked it, I re-fitted the door and front wing to make sure everything lined up. A bit of fettling and all was ok, so it was time to fit the outer panel. I still need to fit the closing panel on the scuttle, and repair the windscreen pillar outer section (the inner section is already done). I will tidy up the welds, apply seam sealer and some primer to keep it free of rust. The outer face of the stiffener and inner face of the A pillar were painted in weld through primer before welding. When it is all finished, the inner cavities will be treated to a generous coating of waxoil or similar.
Here are a couple of pics:
'I intend to live forever - so far, so good'
First job was to fit the inner stiffening section, then I tacked the outer panel in place. Having tacked it, I re-fitted the door and front wing to make sure everything lined up. A bit of fettling and all was ok, so it was time to fit the outer panel. I still need to fit the closing panel on the scuttle, and repair the windscreen pillar outer section (the inner section is already done). I will tidy up the welds, apply seam sealer and some primer to keep it free of rust. The outer face of the stiffener and inner face of the A pillar were painted in weld through primer before welding. When it is all finished, the inner cavities will be treated to a generous coating of waxoil or similar.
Here are a couple of pics:
'I intend to live forever - so far, so good'
renaultvation
Well-Known Member
Here it is from the other side. Welding looks a bit messy on the leading edge. I first plug welded the join, then seam welded it, but the welder got a bit temperamental on the seam weld. Hopefully it is strong enough, particularly as the original was only a few spot welds.
I screwed the inner and outer panes together and plug welded, then welded the screw holes.
'I intend to live forever - so far, so good'
I screwed the inner and outer panes together and plug welded, then welded the screw holes.
'I intend to live forever - so far, so good'
renaultvation
Well-Known Member
Had good morning on the car, fitted a closing panel to the top of the 'A' pillar and started work repairing the corner of the windscreen aperture and windscreen pillar. It's a tricky little area which includes a drainage channel at the bottom. It will take a while to fix this. However, it was one of those days when the welder seemed to sing and it all seemed simple.
'I intend to live forever - so far, so good'
'I intend to live forever - so far, so good'
renaultvation
Well-Known Member
Despite the weather, I made it back to the workshop this morning while Liz watched the tennis. First two pics show where I left off last week and third pic shows today's progress.
'I intend to live forever - so far, so good'
'I intend to live forever - so far, so good'
commeracer
Well-Known Member
Good progress
"You,re only supposed to blow the bloody SLIDING doors off"
Founder of the 6 speed club
"You,re only supposed to blow the bloody SLIDING doors off"
Founder of the 6 speed club
renaultvation
Well-Known Member
Had some time off work last week, so managed to get some inner wing work completed. As usual, it was a case of remove new metal to expose remains of rusty original, remove rusty remains and fabricate new panels. I have included a photo of my second rust original car which I use for reference and critical dimensions when fabricating new panels. I have made a slight change to the profile at the front to remove a rust trap.
