Friday, October 27, 2006

Welding, Part 2

Well, at last the end of the welding is in sight. This is the final structural stuff, and after all of this I can get on with building up a new rolling chassis.

As discussed under the first welding entry (Nice one Nigel) the new framehead was on, but as a precaution a further weld to the original tunnel was made, through a precut slot.

Also to be finished was a small plate underneath - hence getting the car high up in the air, where the original tunnel lower panel had rotted out. They all seem to go here as water collects through the pedal holes and has time to eat it out from within. I had cut back the rot and this left a 6 x 4" hole to be plated up, to meet the new framhead panel.

Patches were also cut to size to plate over the master cylinder holes in the chassis bearer (they were for LHD).

Finally an additional plate was made up to entirely cover the old pedal holes on either side of the tunnel, and add further strength to the tunnel at the point where the new framehead is welded up to the tunnel. This was made up in one piece, with folded edges being welded onto the floors themselves. This was fully seam welded all round.

Here it is, the nice all new framehead and associated panels, all aligned, fully welded and ready for painting.

I am sure the purists wouldn't be happy with the visible welds, but it is all going to be out of sight eventually. My main objective is to build a good looking car, which is structurally sound and easy to maintain. Once these areas are fully primered, seam sealed and have a number of coats of chassis black over them they should be good for years.

The removal of the original pedal holes also removes a possible water trap which has to be a good thing. The last welding job (for now) was re-welding a captive nut on top of the old axle, as one had sheared off. Welding will resume once I have decided on the amount of floor drop needed. Then I can relocate the gear lever and handbrake too. I have seats and a dashboard on their way which will help me mock up a seating position and make some decisions - at last I am building again !!

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