Rustoration
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- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Putting right earlier mistakes today.
Taking you back, I’d made a pigs ear of removing the panel over the rear arch, so thought trimming the edges and inserting this strip…
… would be the solution.
But I realised I was introducing new probs, specifically creating the inner fold along that weld line, and the potential for warping as the slightly uneven gap closes on welding.
So I cut it out, and then made a broader strip,…
…clamped it to the panel and scribed along the top edge so I can get a good, tight, even, join. Carefully cut along the scribed line, and offered up the strip to fine tune it.
Then cut it into three sections so it fits my folder (cut with snips so I don’t lose any material and create more gaps), and folded it
See how well it fits?
Chuffed. Just have to avoid making a horlicks of welding it in…
Taking you back, I’d made a pigs ear of removing the panel over the rear arch, so thought trimming the edges and inserting this strip…
… would be the solution.
But I realised I was introducing new probs, specifically creating the inner fold along that weld line, and the potential for warping as the slightly uneven gap closes on welding.
So I cut it out, and then made a broader strip,…
…clamped it to the panel and scribed along the top edge so I can get a good, tight, even, join. Carefully cut along the scribed line, and offered up the strip to fine tune it.
Then cut it into three sections so it fits my folder (cut with snips so I don’t lose any material and create more gaps), and folded it
See how well it fits?
Chuffed. Just have to avoid making a horlicks of welding it in…
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Tacked in the angled strips
Offered up the panel to check the fit
Scribed along the edge, then used a straight edge and cut it.
Then filed down the top edge of panel to match
Here’s how it fits together
Offered up the panel to check the fit
Scribed along the edge, then used a straight edge and cut it.
Then filed down the top edge of panel to match
Here’s how it fits together
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
Re: Rustoration
Much respect for the work you are taking care of, keep up the good work! These reparation take much time!
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Welding in the edge flanges. Not quite finished, and nothing dressed back yet. But it all went together much as it should.
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
This isn’t as straight as I would like
Wasn’t careful enough. Cut at the top and pull out
Messily welded again (3 times!)
Ready for the panel, must admit I wasn’t looking forward to it. Bonding sealant first.
Tack along top edge, and start the puddle welds.
More puddles
Start the butt, penetration good after a blow-through!
Pleased with this, got my settings pretty nice
Then top edge of the angled strip…. and my gas ran out.
So, grinding and power-filing.
Didn’t completely escape warping… but could be worse.
Wasn’t careful enough. Cut at the top and pull out
Messily welded again (3 times!)
Ready for the panel, must admit I wasn’t looking forward to it. Bonding sealant first.
Tack along top edge, and start the puddle welds.
More puddles
Start the butt, penetration good after a blow-through!
Pleased with this, got my settings pretty nice
Then top edge of the angled strip…. and my gas ran out.
So, grinding and power-filing.
Didn’t completely escape warping… but could be worse.
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
That last photo was taken before I started the top edge of the angled strip, and the first warp popped out, so you never know, I might be lucky after I get more gas…
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Starting on the next bit
The ends are ok
Bit rubbish at this end, and the brackets are ropey
The ends are ok
Bit rubbish at this end, and the brackets are ropey
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
My Lidl auto darkening helmet provided good service for 5 years or so, but it’s head band has failed in multiple places. Banjaxed.
New helmet arrived, tried it today - it’s like night and day! So much easier to see, more comfortable, more adjustable. I could see that the arc was blue!
https://www.weldingsuppliesdirect.co.uk ... elmet.html
New helmet arrived, tried it today - it’s like night and day! So much easier to see, more comfortable, more adjustable. I could see that the arc was blue!
https://www.weldingsuppliesdirect.co.uk ... elmet.html
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Cleaned off that last weld and stuck some primer on
Took off the cover strip, and marked out for cutting
A sorry state…
Took off the cover strip, and marked out for cutting
A sorry state…
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Cut out section, and in an effort to get good butt joints, trimmed the edge with a flap disc to a line scribed off a straight edge. I just can’t cut straight first time!
Then cut a section of new metal, divided into 3 so it fits my bender, and cut out a profile to match to.
Then cut a section of new metal, divided into 3 so it fits my bender, and cut out a profile to match to.
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Bender failed, so repaired it.
Fabricated the three strips, and tacked them together.
Pondered how to accurately cut the lower edge for a bit joint, couldn’t actually get the piece onto the inside of the hole for scribing. Then remembered I still have the scrap piece, so used that.
Came out pretty good after a bit of filing.
Laid aside now while I do the bracket area at the rear. Looks like it’s tricky as there’s a joint there.
Fortunately the rot does not extend noticeably internally, but it’ll be in the joint.
Fabricated the three strips, and tacked them together.
Pondered how to accurately cut the lower edge for a bit joint, couldn’t actually get the piece onto the inside of the hole for scribing. Then remembered I still have the scrap piece, so used that.
Came out pretty good after a bit of filing.
Laid aside now while I do the bracket area at the rear. Looks like it’s tricky as there’s a joint there.
Fortunately the rot does not extend noticeably internally, but it’ll be in the joint.
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Duplicate post
Last edited by RogerT on 30 Apr 2022, 10:07, edited 2 times in total.
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
But when you get an itch, you just have got to scratch it…
And you end up with a bigger hole.
Needs a plaster, made of 1.6mm for easier welding. Cleco pin just for handling purposes, to help make sure I don’t drop it somewhere awkward.
And you end up with a bigger hole.
Needs a plaster, made of 1.6mm for easier welding. Cleco pin just for handling purposes, to help make sure I don’t drop it somewhere awkward.
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.
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- Registered user
- Posts: 1844
- Joined: 10 May 2013, 11:59
- 80-90 Mem No: 13706
- Location: Central Scotland
Re: Rustoration
Welded in one patch, then started putting in the flange over it.
Realised I needed to prime under it, so cut it off again…
Realised I needed to prime under it, so cut it off again…
Have you ever seen an unhappy fool?
88 Transporter with hitop camper conversion, 1.6td.
88 Transporter with hitop camper conversion, 1.6td.