Green Ale
Posted: Sun Jul 20, 2014 8:32 am
Welcome to Project Green Ale
This is my hospital job and on the road to recovery is the driver side floorpan outrigger.
The floorpan previous repairs showing signs of rust and is holed. Also, the ourigger has corroded.
The inner sill is in need of repair. The flange required for attaching the splash panel is lost to rust.
I'm on a very limited budget so I've decided to hammer form the repair panels. Here is the roughed out panel.
After a bit of trimming and cleanning the panel is ready for welding.
The panel is now tacked into position.
A cardboard pattern taken from my other PI. Again a bit more trimming to fit and cleaning for tacking.
The outrigger was corroded so I've folded this replacement.
The flange on the outrigger I have welded seperate.
The outrigger welded into place after trimming to final size.
Replacing the footwell section.
I've put in a joggled seam on the floorpan to take the footwell section.
Welded the side section of the footwell which joins to the inner sill and eventually the splash panel will be welded to this.
Here is the welded panel from the inside.
That's it for now! I've painted red oxide, so on the next session I'm fettling the welds and replacing the splash panel.
This is my hospital job and on the road to recovery is the driver side floorpan outrigger.
The floorpan previous repairs showing signs of rust and is holed. Also, the ourigger has corroded.
The inner sill is in need of repair. The flange required for attaching the splash panel is lost to rust.
I'm on a very limited budget so I've decided to hammer form the repair panels. Here is the roughed out panel.
After a bit of trimming and cleanning the panel is ready for welding.
The panel is now tacked into position.
A cardboard pattern taken from my other PI. Again a bit more trimming to fit and cleaning for tacking.
The outrigger was corroded so I've folded this replacement.
The flange on the outrigger I have welded seperate.
The outrigger welded into place after trimming to final size.
Replacing the footwell section.
I've put in a joggled seam on the floorpan to take the footwell section.
Welded the side section of the footwell which joins to the inner sill and eventually the splash panel will be welded to this.
Here is the welded panel from the inside.
That's it for now! I've painted red oxide, so on the next session I'm fettling the welds and replacing the splash panel.
) to give you some work because I need to get some tricky bits of panel forming like this done for my restoration of NAM, my London-Sydney/Monte/World Cup Land Crab which I must get on with next year ....... It needs a lot of these sorts of repair panel! I am always looking out for NOS ones (no one bothers with repro stuff for Landcrabs 
) so I am going to have to see if I can get my skill level up to yours which I doubt!