Lots of welding to do - in what order?

Just landed myself a little project.
Its an 85 ninety which looked fair on the surface. Just below the surface though its a different matter.

But, seeing as it was cheap, a new chassis is out of the question financially.


But it does need:

• Bulkhead top repairs
• Bulkhead bottom bracket renewals
• Footwell replacements
• Battery box repairs
• All outriggers

Now I've read around and am fairly confident in each job - the problem being that usually people suggest doing each job separately and using the body etc as a jig to ensure correct placement.

Seeing as I need the body completely off I'm struggling to work out how to do each job and ensure all the bits get tacked on in the right place.

Just fearful that I might get it all together then find the hardtop never fits again!

Lots of pics on my website in sig.


So in what order do I do it all?

who's the pretty blonde piece called katie, and welcome to loony zone. as for the top bulkhead you're going to have to temperarily bolt the screen back on to be sure it will fit when you are finished and so on and so forth with all other repairs, long and slow winded i know but the only way to be sure of fitment once finished welding. good luck.LEE

bevhelee said:

who's the pretty blonde piece called katie

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I think you'll find that that is Joss Stone

As for welding. Do the outriggers on the chassis first. You can measure the position from the 90 as is now and there are chassis diagram avaliable on the net or Rave CDs.

Then build a jig for the bulkhead and do the welding off the truck.

Alternatively, just look for a replacement bulkhead in better nick

andyb66 said:

I think you'll find that that is Joss Stone

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Indeed it is!

andyb66 said:

As for welding. Do the outriggers on the chassis first. You can measure the position from the 90 as is now and there are chassis diagram avaliable on the net or Rave CDs.

Then build a jig for the bulkhead and do the welding off the truck.

Click to expand...

Sounds like a plan. Though I have read a bit about the outriggers possibly sagging. I can copy the existing ones' positions but are they correct now?

andyb66 said:

Alternatively, just look for a replacement bulkhead in better nick

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Aah but might be just as bad inside..... better the devil you know. I think this one is desitned for repair for the moment.