The cutting disc saga

[finishing touch]

Attacked mine with a cutting disc today.


I felt like Monty Python in that tree branch sketch.




Paul G

[TVRees]

Looks like a major job, but I see you're a professional welder, so that will be a big help.

Please keep us posted regarding your progress.

[finishing touch]

TVRees said:

Looks like a major job, but I see you're a professional welder, so that will be a big help.

Please keep us posted regarding your progress.

Welding is the easy bit. IMHO anyone with reasonable hand/eye coordination could use a modern MIG with just 30 minutes or so instruction.

I find that by far the hardest part is in the making of the replacement panel. The better the fit the easier it is to weld, and consequently the stronger the finished repair.

Photo shows my replacement chassis rail balanced roughly in position. I still have some holes to drill with nuts welded inside to hold the ARB.

Weld up and start on the other side. Never done chassis rails before but I'm assuming the second one goes quicker.

Paul G

[TVRees]

Looking Good !

Did you have to take off the front suspension (FLCA, FUCA, ARB, Shocks, etc.) to do this job ?

AND .....

Let us know, how easy (or difficult !!) it is to weld the inside of the replacement panel ?

And thanks for the welding tips, I'll give it a try one day, maybe !

[finishing touch]

Front inner wing plastic panels removed.
Rad removed.
Long bolt through top wishbone removed so w/b can be moved out of the way.
ARB removed as the brackets bolt to the new chassis. Note holes with nuts welded behind.
(These are 2 x M6 plus a spot weld. I have changed this to 3 x M8)
Air filter box & pipe removed
Power steering bottle unbolted and tied back out of the way.
Carbon filter can thing unbolted and tied back.
Anti lock sensor wire bolts to chassis. Nuts to weld in again.


I would describe it as a moderately easy job, but time consuming, hence a going rate of £800 in a resto garage.


Grey primer must be dry now. Off to squirt (techy term) some blue.


Paul G

[TVRees]

Looking great.

Very tidy welding and thanks for the info & tips. Don't forget to squirt some Waxoyl, or similar, inside the new bit !
Keep us posted with some pics of the finished job and some from the other side.

Edited by TVRees on Friday 29th December 19:48

[finishing touch]

The other side now done and the cars now ready for a wheel alignment session.

Not a lover of Waxoil so squirted chain lube (spray grease) inside.


I have awarded myself "The Order Of The Boot".
Like the ink blot pictures its what I see when looking at this.

HNY

[buzzer]

Very neat, a superb job! I like to see work like this.

Welding is good, can i ask what make and model of MIG you use? Mine is due replacement, its never been any good...

[finishing touch]

buzzer said:

Very neat, a superb job! I like to see work like this.

Welding is good, can i ask what make and model of MIG you use? Mine is due replacement, its never been any good...

Thanks.

It's a Lincoln 210, which is misleading as it's 185 amps, running 15% CO2/argon and 0.8 wire.


Although it's single phase it's an industrial machine and will weld 1/4" plate all day if required.


HNY
Paul G