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Project Rusty.

Discussion in 'Members Vehicles/Projects' started by dieseldog69, Dec 11, 2014.

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  1. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Cleans up with the flapper ;)

    I bought 20 of them by accident, thought it was for 10 at a really good price and turned out it was 20 at an amazing price lol
     
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  2. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Cheeky git, less rust on this thing now than when it was new I think lol
     
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  3. Henry_b

    Henry_b SPARES OR REPAIR

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    Aye, when is the estimated time of completion ;)
     
  4. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    I want to get it done ASAP, end of the month would be nice but realistically mid October for a full 12 months of the road and then it's back and ready for winter recoveries :)
     
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  5. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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    Did a bit of welderising myself today..... Tried out my rebuilt Mig welder on my trilobe nut spinner tool.

    I was a bit concerned whether a 4M long welding torch would be too much, but I am quite pleased with the way the weld has cleaned up. Its pretty thick steel too, so just about max settings.
    upload_2019-9-22_17-41-38.png

    For those not familiar with this tool, it is a 36mm AF headed bolt, welded into a 52mm mm socket attached to a 12mm disc. Pretty heavy stuff. This I can manage :). Rusty 20AWG car body panels.... a different matter. :(.
    car panels are not so easy. :eek:.
     
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  6. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Says you :p
     
  7. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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    I been studying a professional;)
     
  8. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Been a busy shift out there making it better, one weld at a time :)

    Ground off all the little pucks left behind from the old panel removal, silly me didn't realize that there was indeed a special drill bit that you use to remove the old panels and it leaves the remaining panels ready to go :(

    IMG_20190922_153456.jpg
    Quick test fit the new salvage panel.

    IMG_20190922_153517.jpg

    Before I can fit it there is a small repair to do on the rear body cross member.

    IMG_20190922_162630.jpg

    IMG_20190922_164827.jpg

    Quick blast over with some weld through primer to try and protect the repairs as much as possible.

    IMG_20190922_162636.jpg

    Double whammy pic, look at the top curved panel from the roof, there are three holes left from removing the old remnants of panel and above them there are some rot holes where the panel has rotted through from the inside, and then there is my new favourite welding clamp, well now I know what it is for lol

    IMG_20190922_165711.jpg

    Good rear view of the spot welds to show that they have fully fused both sides.

    IMG_20190922_184716.jpg

    All welded in and primed.

    IMG_20190922_174732.jpg

    There is a bit of seam sealing to do on the panel joint but it's great to have it almost sorted.

    IMG_20190922_174739.jpg

    Primed the inside of the panel as the fresh welds will flash rust otherwise.

    IMG_20190922_190611.jpg

    Oh and this is the pic of the rubber fin seal fitted to the tub all sealed up with some sealer to keep muck and water from getting under it and rotting it all out again.

    IMG_20190922_184657.jpg

    A bit more fabrication to do to finish that rear post to the roof all solid again and the rear quarter skin can go back on.

    Never a dull day on the rusty one.
     
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  9. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Bit late after work to do anything noisy as we all have small kids, but I got out and slapped some, paint, yes, lets just say I got out and slapped some paint on it :rolleyes:

    IMG_20190925_192331.jpg IMG_20190925_192314.jpg IMG_20190925_192159.jpg

    Looks much better and a lot more weather proof than the primer ;)

    So how did I end up with silver Hammerite? Well, what happened was, I went to my local hardware store and they had sold out, looked online thinking it will be here in good time for the weekend and voila, one tin comprising 750ml of Hammered SILVER turned up and I had ordered black but it wasn't until I opened the tin I got the shock of my life, but I was thinking to myself only today what I am going to do about the visible side of that rear door post, it seems that I had that question answered for me lol.
     
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  10. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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  11. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Yeah, one of the boat builders here on the island has been singing it's praises loudly as Akzo Nobel have returned to the original formula apparently and it's doing very well again, if a boat builder who sticks it on steel that is going to live in the ocean speaks highly of it then I'm game.
     
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  12. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Well the Mrs. is away at her mothers and with plans with @The Mad Hat Man were scuppered by the inclement weather and then plans with the Mrs. were scuppered by their plans for today I would up back at home, alone :)

    Weather was sketchy as frig but I felt inclined to get out there and attack it in between the showers.

    More ball ache than a kick in the nuts but getting there :)

    Started out looking a bit worse for ware.

    IMG_20190908_182239.jpg

    But it got better.

    IMG_20190929_172012.jpg IMG_20190929_172016.jpg IMG_20190929_172404.jpg

    Still got the inside of the post to remake and although it is done now I forgot to take snaps as in a hurry as having dinner with mum.

    IMG-20190929-WA0008.jpeg

    You can clearly see the old spot weld holes that were welded up and the big blobs where the rot had come through from the inside.

    IMG-20190929-WA0006.jpeg

    It all just needs to be ground back and made to look more presentable and I might even break out the filler to make a proper job of it lol

    Once it's ground back I can then get the outer body quarter panel back on and the back door too, I popped the nut plates out, sanded all the rust off with a flap disc and got them primed and put them back in with a big smear of waterproof grease, filled the crush tubes up with grease too and popped them back in and blathered the whole lot in waterproof grease.

    IMG_20190929_172021.jpg

    IMG_20190929_172024.jpg

    I fear I may need to replace the lower door hinge as it seems to be seized, well, difficult to move by hand unlike the top hinge :rolleyes:
     
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  13. Shippers

    Shippers Well-Known Member

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    Jesus that's some weldathone your doing.. always look forward to your updates...inspires us all to keep going...as an update to mine just bought this week a techno weld 180a synergenic kit to finish my P6 and build roof bars for 101...
     
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  14. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    I wouldn't mind but I'm not even close to finishing yet lol

    Thank goodness I bought myself a leather welding jacket, I got a couple of spatters first pull of the trigger and thought "where's me jacket" popped it on and right as 9 and away we go.

    IMG_20190929_225913.jpg
     
  15. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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    They are good, but not ideal in the 35degrees we had earlier :eek:
     
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  16. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Good lord no but now it's cooler it's one of the best investments a budding welder can make, especially if welding overhead.
     
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  17. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Whilst sitting in the front room watching garbage on TV, I felt an urge :)

    No, not pawnhub, you filthy child :p

    Whilst the cat is away so they say lol

    IMG_20191003_171353.jpg

    Best do another coat an slap some top coat on it :D
     
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  18. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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    The Times eh?

    Very South Coast :D
     
  19. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Ground workers call me middle class, can't think why?

    IMG_20191002_132241.jpg

    New carpet in the digger and new slippers too :)

    Oh and I sit there reading the Times :D
     
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  20. dieseldog69

    dieseldog69 Well-Known Member LZIR Despatch Agent

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    Been outside to attend the Rusty one.

    No photos sadly, went with the intention of getting the little die grinder out and grinding back the welds on the repair sections on the top of the door post, battery went flat quick, guessing that I used it a lot more than I thought at the weekend, bugger :oops:

    But there has been a problem with water ingress from the front windscreen for a while now, basically since the new screen was fitted last year, got the scrubbing brush out and scrubbed the seal and as much as I could behind it with a bit of elbow grease and above the seal by a few inches, got the masking tape out and the mastic gun, dried it with paper towel and wiped it over with some meths and ran a bead along the seal, smeared in with a finger and we shall see how well it works, but judging by the mahoosive gaps up there I guess I might need to do it again later on when I attack some rust spots on the front roof edge.

    Bit of time and still a bit light so I set about the passenger side foot well with the silver Hammerite and made it silver again over the red primer.

    Its pitch black out there now and I just got the tarp back on in time before the rain came.

    Time to cook me some dinner :)
     
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