Club 80-90 Forums

Hi Guys,

After having tackled the upper window rot from autosleepers poptop screws and resulting rust I am now ready to tackle the lower surround, mainly in the corners. The NS is in worse nick, although most of the colouration is rusty water that stained the white paint.







Can anyone suggest the best course of action. Should I build up the lip as in the wiki and grind flat with slither of filler? Or cut out completely? Can I replace the lip with one piece of steel or do I need to keep it 2 pieces wide? Can I cut both bits out and just replace with a thicker gauge?

Cheers

you can do it loads of ways, big lumps of mig and loads of grinding, get the repair bits and mig them in ,still loads of grinding, make the bits yourself and weld in, what you have to remember is the lip outwards is the seal face and is also seen, so need to be right. im doing the mally in the next couple of days, but its a touch worse than that but same idea
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Cheers MM, will you be taking pics etc like your other rebuilds of the mally?

Also I am a bit unsure what you mean by "he lip outwards is the seal face and is also seen, so need to be right." Do you mean the vertical lip that I need to repair effects the seal in terms of it may protrude if not even?

the vertical lip just needs to be the same size/shape as the rest and of course in line. get this right and you have a fighting chance, the horizontal part justr in front is the major part of the sealing face, so whilst a nice gen rubber will have some compliance to cater for irregularities , the better you get it the better the chance of a seal, also as you know you see the front radius of this so visually its important, and yes full pickies nowt hidden
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Cut out and weld in new...

Or on the other side....

Blimey you cant tell at all youve let a piece in there! Cam i ask how do you bend the piece to match the curve of the surrounding area? Specific round bars etc?

pay attention there ! note the saw cuts then he bent it and migged the cuts up , thats one way there are others, see the mally vagon for a different method,as i just done both sides,
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bmouthboyo wrote:Blimey you cant tell at all youve let a piece in there! Cam i ask how do you bend the piece to match the curve of the surrounding area? Specific round bars etc?

Yup just tried a few different "round things" to hammer it around to get the same curve. Can't remember completely but I think it might have been a socket set long extension bar that I used...

awe$ome work!

boatbuilder wrote:

bmouthboyo wrote:Blimey you cant tell at all youve let a piece in there! Cam i ask how do you bend the piece to match the curve of the surrounding area? Specific round bars etc?

Yup just tried a few different "round things" to hammer it around to get the same curve. Can't remember completely but I think it might have been a socket set long extension bar that I used...

Can I ask what the slits are for? I don't mind the odd bit of welding but find the fabricating much harder with lack of tools, experience etc. Are the slits just to let it fit in better or are they for the curve?

other easy way if you dont fancy that or hand making is to bend a bit of 1/2" bar and shape your bit over it
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