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Resident Spanner

One more of those non-breakdown things.

Well, sort of, the parents Jaguar parking up outside with the brake pads on fire and smoke pouring out was probably a sign that it needed some work  
Anyway, usual Ford (X type) problem with knackered seals on the handbrake side making the caliper sieze on, caliper duly exchanged, new one fitted, brake line bled, still felt a bit spongy on the pedal, so I went around with the jack to the other side to bleed the rest of the brakes.
The car got about 3 inches in to the air and then the jack promptly punched through the sill...ah, bit of work required then.







It goes all the way from back to front - far enough forward that the a pillar is going to need surgery and the wings have to come off, rotted from the inside out, both sides of the car
Chris M Wanted a V-10

Do you do welding?
What with the sills and the 500's gearbox, you've got your work cut out for a bit, haven't you ?
Frank Bullitt

Crikey - a previous dodgy repair?
Resident Spanner

Chris M Wanted a V-10 wrote:
Do you do welding?


Do bears shit in the woods?
If I may blow my own trumpet, I'm shit hot when it comes to welding cars up. I've had a few classics brought my way because the owners wanted invisible repairs in the metal so they could pretend it was all still original :D

Bit naughty but that's up to them!

Still going to be a hell of a lot of work though, they've gone so far I'm going to have to weld a brace across the door holes to stop the chassis from bowing when they get cut out I need to take so much away.
Roadsterstu

gonnabuildabuggy

How old is the X type?

FRV just had welding but that was just lots of small holes caused by poor accident repair (new sill not rustproofed properly) 9 yrs ago.

Would that have been accelerated by the plastic over cover trapping mud/moisture?
Twelfth Monkey

I've said it before and I'll say it again - I'm in awe of those who don't recoil in horror at anything mechanical, let alone have the nous and confidence to DIY.
Bob Sacamano

That's pretty shocking. I'd be tempted to scrap it on safety grounds rather than attempt a repair - you could end up chasing bad metal looking for good.
Resident Spanner

gonnabuildabuggy wrote:

Would that have been accelerated by the plastic over cover trapping mud/moisture?


Probably, there was quite a lot of crap wedged in the back of it, some of it covering the breather holes halfway down the sills, it's 15 years old, so not entirely surprising for something based on a Ford

With it going from the rear inside out it's something that the application of about 2 worth of cavity wax at the factory would have prevented, there's nothing there inside, just e-coat over the bare steel.
gonnabuildabuggy

Resident Spanner wrote:
gonnabuildabuggy wrote:

Would that have been accelerated by the plastic over cover trapping mud/moisture?


Probably, there was quite a lot of crap wedged in the back of it, some of it covering the breather holes halfway down the sills, it's 15 years old, so not entirely surprising for something based on a Ford

With it going from the rear inside out it's something that the application of about 2 worth of cavity wax at the factory, there's nothing there inside, just e-coat over the bare steel.


Time to bring back Waxoyl!

I've liberally waxed the MX5 sills and chassis, though it;s due it;s annual top up after the recent welding. Perhaps I need to do the FRV as well, though the repaired sill has been done as part of the repair.
Resident Spanner

Yeah, the MX-5 got the sills filled with Dynax when they were repaired, the 406 has had some too, even though there's no signs of rust.
Alf McQueef

Ah, that reminds me of our Mk1 Focus. Everywhere you looked, there was rust and more rust...
gonnabuildabuggy

Alf McQueef wrote:
Ah, that reminds me of our Mk1 Focus. Everywhere you looked, there was rust and more rust...


What reg was it? Big little's 53 plate is suprisingly rust free, whereas my Y (2001) Plate Mondeo has rusted nicely on the inside of the bottom of the doors when I owned it back in 2006.
PG

It'll be as solid as Triggers broom by the time you've sorted.
Resident Spanner

It will, the wiring loom has just chafed through so I patched that yesterday, today the breather hose split and it was running like a bag of nails.
Patched up with some silicone tape while I can get a part.

Won't be buying another
TreVoR

I've just worked out how a wiper and and park switch work in the real word without diagrams.  The Defender rear wiper now wipes and works off the switch.  I am well pleased with myself.
Resident Spanner



I've just built a little circuit to do that automatically on the buggy 'cause I don't have enough wires in the connectors to do it the old fashioned way :P
TreVoR

It had me scratching my head for a while, it must be said.  I used the old rear door loom from a Discovery for the proper connectors - Land Rover want 95 plus VAT for a new rear door loom!    The scrapyard one cost me 12.
Resident Spanner

I must admit the first one I looked at made me scratch my head until I realised the seemingly useless second earth was to drain the motor fast enough to stop it skipping the track.
TreVoR

Just three feed wires on the LR one and five connectors on the motor - no switched earth.  Shorting the switched live to the live motor feed and park switch live made it work as it should.
Resident Spanner

Usually earthed through the case and then another earth for the track circuit?
TreVoR

Not on these. The motor has a direct earth and a positive feed from the park switch. The park switch gets a switched feed and an ignition feed and in addition to the wire to the motor live.  To get it to work, I had to bridge the switched feed and the motor live.

I mistakenly thought that the park switch would send power to the motor when the switched live was enabled but apparently not. The motor needs a direct switched live too.

The old motors had an extra connection and this was done via the dash switch but not the newer ones, hence the confusion and not being able to make heads nor tails of the wiring diagram!
Resident Spanner

I forgot to mention the best bit of this one....the front....





Had to do all the front inner through the hole I cut to put enough strength in so I can cut out the middle and rear of the sills because the car started to bow even with the doors braced
Roadsterstu

It started to bow?  
Resident Spanner

Yeah, the structural skin on the right there is detached down the whole length of the car at the bottom, it's just floating  
Grampa

Savable (obviously anything is savable, but at reasonable cost?) or is it heading for scrap?
Resident Spanner

To have it done at a garage would probably have been 800+ per side.
Resident Spanner

Here's the rest of that side....





JohnC

What a lot of work!
Resident Spanner

Spent an hour or two with the Angry Grinder and one of those b****d rotating hellspawn pieces of shite they call wire wheels, cutting the rot out and tidying the main bit up - I'm going to make and weld a replacement in here before I touch the rear corner because frankly it looks like this:



Which means I'm going to have to cut the rear arch tub out to fix it properly - I could just knock a bit in the seam there but it'd come back through eventually from behind so choppy choppy time.
Anyway, I'll weld the middle in first so it doesn't do an impression of a chocolate fireguard. Angry Grinder at work:



Plus some time with the Hellspawn spinny thing of doom and some carbide burrs sorted the rest of the steelwork out, so I fixed it quick with the Yellow-Paint-Of-Strutural-Integrity:





The missing bits are, errr, go-faster holes.
Resident Spanner

The front inner sill and outer corner was actually repaired before the above was chopped out to put some strength back into the car before I cut more away - as the floorpan was sagging slightly:



There, bit of silver paint and it's fixed!

Corner of the floor welded back in and then the middle structural panel patched up over the top:



Bit of ropey outdoor welding - did the beginners trap and put too much zinc weld-through primer on the backside and had it bubbling through the welds, doh (nothing wrong with it, just not as pretty as I like)



Thank God for flap discs....



Also welded the front mounting point for the wing on there. Old clips that Grampa mentioned were knackered so I just popped a steel rivnut in instead.

And some poor quality pictures but as you can see was rather late when I got on with this bit - welding by torchlight is...interesting.

Middle inner sill in - I just knocked the stiffening windows in with a hammer + chisel and didn't bother making the little rounded edges in them - so they don't quite match the top halves in the way they look - but so long as they give the strength it's not exactly the worst issue.
Speed over finesse for this panel, I'll worry about looks on the outer!





It tapers from one end to the other and up from front to back so bowed a bit whilst stretching the metal to form the windows, took an hour of swearing at it to get it to go back flat!
Chris M Wanted a V-10

I'm most impressed by the weldable Malted Wheaties box.  In my part of the world, it's made of cardboard......
Resident Spanner

You can weld anything with enough heat!
Chris M Wanted a V-10

Resident Spanner wrote:
You can weld anything with enough heat!

So long as it hasn't caught fire first !
Resident Spanner

That's just helping it on the way to nuclear fusion.
Resident Spanner

I reckon I might have got that pad a bit hot sorting out that panel*....




*Not finished yet if you're wondering, need to weld the bottom edge on as I couldn't manage two curves that close together in the folder - hence the holes so I can bolt it up to the car and then tack the bottom on. Also fucked up a bit as there's supposed to be a dip in that left hand side to slide under the centre one. Hammertime tommorow should fix it - or I'll cut it and just weld it in sitting a little lower.
Resident Spanner

Well, it's been slow going, mainly due to replacing half a rover 75 and the suspension on the MX-5 mid way through..oh, and I modified the welder to go faster:




Anyway, all those little rear panels are made and in, and the centre reinforcement, all that was left was to weld the front one up from earlier in the thread:



And try it to see if it slotted into the recievers properly on either side. I'll say that's a yes, because I pushed it in, it went 'ping', sat perfectly in place and now I can't get the fucker back out. Looks like I'm spot welding to the sill through the zinc paint then...

No, I haven't missed some, it's where I put the tacks, don't know why but the camera/photobucket seems to have blurred them with noise reduction, should have .png'd 'em.

I'm working on the outer skin now, nearly ready to weld in but didn't get any pictures because:

a) It's freezing
b) It was dark
c) I've made a right balls up of putting some of the ribs in so you're not looking until I fix it
Roadsterstu

Impressive man skills  
PG

By heck that is all impressive stuff.

Do you parents have another care to use, or are they standing over you to finish it?  
Resident Spanner

My mother passed away earlier this year so my dad's using her Mazda atm. Well, until he needs more seats and boot space and then I get roped in as taxi.

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