Rust repair bulkhead

mick the builder said:

i used to live in N19

Click to expand...

.

Made the wing brackets this morning as old ones looked pretty rusty. Measure, cut, bend and drill, primed.
Put the door back on just to make sure all is well.


Layed out the stencil I made previously.
Got busy with my drill and cutting disk.

Previous foot well for hole reference.



Going to remove bulkhead tomorrow and finish up welding and grinding and hole drilling.

Anyone have anything to say about galvanizing?

Have a search. Deff.alley need a jig to stop it warping but there was talk about the prosses carried out.

Mine has square bar welded to the footwells where the pressed bits are in your last picture. I presume to stop the thin footwell plate from rippling.

I made the footwells from 2mm sheet so has a lot of strength, If I run a angle between the feet to keep it true, what happens where there is no way for the zinc to flow over the feet as there is a bolt running through it?

I guess it might be better to tack weld across the inner side of the foot at the top keeping the angle slightly away from bolt hole and cut it off after thus minimising weakness of water penetration from wheel.

Frosted said:

I made the footwells from 2mm sheet so has a lot of strength, If I run a angle between the feet to keep it true, what happens where there is no way for the zinc to flow over the feet as there is a bolt running through it?

I guess it might be better to tack weld across the inner side of the foot at the top keeping the angle slightly away from bolt hole and cut it off after thus minimising weakness of water penetration from wheel.

Click to expand...

Maybe it's just folklore about them twisting. My out rigger bolt holes were galved right through, so don't know how mine was braced. Rumour might have been started by companies who galv bulkheads and charge £1000 for the privileged.

Not much to report other than lots of drilling, welding and filing square holes on the bulkhead.

Sent bumper, capping and door sills to blasters.

Made some rear door corner brackets today and started repairing the capping.

Went off on holiday for bit but back at today and managed to fix the welder issue I had. If you have a Clarke mig or other check your wire spool carrier pieces.
Mine had a load of ridges which given me no end of feed problems.
So today I filed and sanded them down the difference is astonishing!
Its like so easy to weld now I can't believe I have been fighting this thing for years!

No pictures just wire wheeled the arch liners after have a small controlled fire in each to remove the wax oil.

Then started cutting out rotten metal from the bumper and welding in new pieces before galvanising.

Tomorrow should have pics of progress.

Check your mig wire carriers!

Xmas came early today!
Loads of bits of zinc to file away but really pleased with results had it done at Southeast Galv.

Was worth all the pain

View attachment 131874 View attachment 131875 View attachment 131878 View attachment 131879 View attachment 131882

Sweet

Wow! That bulkhead! Those inner arches!!!