Crashbox's Series 3 rebuild thread

[big red]

I have repaired the top part of the bulkhead and will take photos once the welds are dressed up.

I'll be interested to see them. I need to do them on my wife's 90, but I'm not really fancying it much

 

[hollydea]

hi great thread we are intrested to see how it progress and the pics of the bulk head repair we have just got our 1st series 3 which wants some sorting we await more

 

[crashbox]

Thanks for the encouragements, the part of the bulkhead I am repairing is the part that is hidden by the window frame. It looked solid until I took the window off and the ledge was rotten most of the way along. I have fabricated repair patches and welded them on, after cutting out the rot. Not an easy task but I will post photos when done.

 

[johnny curt 1]

Thanks for the encouragements, the part of the bulkhead I am repairing is the part that is hidden by the window frame. It looked solid until I took the window off and the ledge was rotten most of the way along. I have fabricated repair patches and welded them on, after cutting out the rot. Not an easy task but I will post photos when done.

same thing i had to contend with ( its a bugger of a job innit )

 

[waldershelf]

same thing i had to contend with ( its a bugger of a job innit )

I did the same repair on a S111 I had. A pig of a job and for some reason its one of the pieces you can't buy as a repair panel.

 

[crashbox]

Its not an easy task but after seeing Johnny's effort I was encouraged to repair mine. If I get a minute I will finish it and post some pictures.

 

[crashbox]

Well thats the bulkhead upper part repaired, you can see the before and after. This will be hidden by the windscreen frame but I will add mastic to help the rubber seal. Next job is to cut out and patch a small bit on the lower bulkhead.

 

[nrgserv]

looks a nice repair!

 

[crashbox]

looks a nice repair!

Thanks, I ground down the welds then gave it a skim of cataloy. I dont like catty but it was just to dress it up a bit, even though it will be hidden.

 

[crashbox]

Decided to completely strip down the bulkhead to get better access for some small weld repairs and a complete respray. Here she is in her naked glory.

 

[johnny curt 1]

Decided to completely strip down the bulkhead to get better access for some small weld repairs and a complete respray. Here she is in her naked glory.

aaahhhh the memories

 

[samc88]

That bulkhead looks quite decent. I need to weld the drivers side footwell up when I do mine.

 

[crashbox]

Both footwells have been done by a previous owner. The big hole above the gearbox tunnel was a series of cuts. Someone must have needed access but just folded the metal back and pop riveted a plate over it. I have cut it all away and will weld a patch over it.

 

[owl]

The extra effort now will pay off latter on, there's no satisfaction when you've finished if you look at it and wish you had just done this or that while you had it in bits.

 

[crashbox]

I agree with you Owl. Here are the before and after on the repair to the hole above the gearbox tunnel. It is flat now but will look better with some primer.

 

[crashbox]

Next job is the bottom footwells at the gearbox tunnel. I have cut out the rot and will now go and fabricate some repairs.

 

[crashbox]

So I thought I had cut out enough metal to get rid of the holes but no, I found more tinworm so I cut out a triangle, welded new metal in then welded the outer repair in. I will dress it up with the grinder tomorrow. Solid repair. Will also repeat the repair on the other side. Its handy when you can tip up the bulkhead to suit whatever repair you are doing.

 

[crashbox]

To be honest, the welds look pretty bad in the photos but do look much better when seen in the flesh...honest. I will post a piccy of the welds dressed up later.

 

[jamesmartin]

not too bad at all ,emery discs are good for flatting welds back

 

[samc88]

You're certainly better than me with the welder
What type of welder are you using?