Club 80-90 Forums

RogerT wrote: ↑09 Jan 2023, 19:58 Thinking ahead



Sliding door rail panel, in prep courtesy of Plasticman…

Needed to make a proper job of it

I got that panel. It's brilliant and thicker steel than original.

In transit as I type!

Test fit of the outer B. Revealed an error when fitting the inner sill, as the panel lines on the new outer B don’t match up! I hadn’t measured a datum when removing the inner sill, but to be fair to myself, this is what I would have had to measure to…



The fit is only 5-7mm out, and looking at the old mess there’s no way I would have got better than that.

So my plan is to cut the outrigger to allow the inner sill to be lifted with the JP, then weld it up again. Seems like the simplest way.

Proposed cut lines…

This wedge out to allow space to close, and the rear cut to allow the pivot.


Then this one where the outrigger supports the sill.

Measure twice, cut once, or better still don’t cut at all. After careful trimming of my outer B piece, I decided no cuts were necessary!



With it in place other parts could be trimmed.

He loved coming away in the van, but he’s had his last trip anywhere. Was at least 14 yrs old, we got him as a rescue 10 yrs ago.

Sad times!

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Indeed, tears all round. Gradual decline over the past few months, usually had to be hand fed to get him interested in food but even yesterday he enjoyed a chase with his pal.

Similar symptoms with ours, a few years back.
One of the toughest calls I've ever had to make.
Sincere sympathy to you and all your family.

 

Back to it.

Formed this


to go here


like this


in the expectation that it functions like this


See the return lip meeting up with the edge of the outrigger, which is very vulnerable to road spray.

From this…



…to this today



Further fettling of the outer B and how it fits, looking good at this stage.

Filling in gaps on the inner B pillar, and the infill between the battery box and outrigger.

Last piece of the inner B pillar



Horrible snotters on part of it, but pretty awkward getting into the corner. Pleased with the bottom corner though

Nice one!

It’s tonight to garage how how to go when repairing to old “rusty metal” or you left with a lovely hole to patch up too


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I’m cutting as much rust out as possible, especially on these structural bits. Welding onto rust is just asking for trouble I’ve discovered!