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22nd February 2009

Back in the garage with the start of 'Man Flu'. Finally got on with final fitting and welding on the OSR inner wing repair section. It looks to have gone well. There appears to be a slight amount of beating required just at the point where the top deck will meet the top of the rear wing just behind the non existant B post, the profile isn't quite right ... yet.

Having done that, I felt that I needed something easy to do as I was feeling under the weather. So I decided to try to remove the plate a PO had put over the filler neck hole. After some careful stripping of more of the dreaded green primer I discovered some original 1956 Glacier Blue paint, yet more proof that this was the original colour of the car. Having exposed the plate, I couldn't see how it was fixed in place. There were no welds or brazed joints, so I tapped it gently from inside the boot and it popped straight out! It was only held in place with some body filler! After this success I set to with the stripping wheel and cleaned off half of the rear deck back to bare metal. No rust anywhere just a tiny dent about halfway up the length of the boot lid apature, an easy fix for a seasoned pro with a hammer in his hand.




Next thing is to order a few more repair panels, I need both sides of the batterey panel end pieces and a section for the rear of the inner wing which has completely dissolved. With my previous repar panel fabrication in mind I may have a go a fabricating this myself using the intact NS as a template.


24th February 2009

Well, as I was still feeling poorly, went back to the garage looking for something else easy to do. I decided to strip the boot lid. There was a small amount of blue paint visible at the trailing edge and I had a suspicion that the whole panel might be blue under the primer. Turns out I was right! it also turns out that there are two small holes in the centre of the boot lid with a crack running between the two. Looks like a job for a TiG welder to me.

18th March 2009

Despite the lack of updates, things are moving along nicely. I bought some HTS2000 Aluminium welding rods from Frost's and had a go at repairing the holes in the middle of the boot lid with quite acceptable results, just a thin skim of filler needed to complete the job.

I had a good look at the rear sections of the rear inner wing panels. Both sides needed a repair piece as mentioned previously. I decided to have a go at fabrication of the panels, nothing to lose and it keeps me out of trouble. Some 2 hours later I'd made both pieces. I had a block machined to enable me to emulate the swage lines in the sections I'd made.

Finally, in this episode, I spent a week watching an item on Ebay and with 23 seconds to go placed a bid and won a real bargain. It's a wing nose piece repair section. Very expensive from Moss(£320), expensive but good value from Sports Car Metal Works(£170) but an absoloute steal on Ebay(£57)! I'm feeling rather pleased with myself with my new purchase, the rest of the family are even more convinced that I'm 'ODD' - Surely not ... Anyway, here's a picture of my latest treasure for you all to enjoy.


The next tasks are to fit the newly fabricated repair pieces to the inner rear wings, fit both rear wings, the Off Side one still needs some TLC with a hammer and some dollies. This will enable me to complete the repair of the front section of the inner rear wing. After that I'll be on the lookout for a rear valance repair section and eventually I'll have to take the plunge and fit the front wing repair section. I think that'll be a serious test of welding skills....


22nd March 2009

So, here we go, fitting of home fabricated repair sections - well one side at least!

The first step was to carefully cut out all the rot on the inner wing panel and then trim the gap for a snug fit with the repair panel. This revealed that a small amount of the floor section under the rear bracing section is rather frilly. This will be replaced once the rear tub is off the chassis and can be turned upside down for access to the area in need of repair. In the mean time the edges were tidied up. the captive nut just under the fuel filler neck hole had to be replaced as the original had a sheared off bolt jammed in it. I couldn't shift it with releasing oil or with heat and I had a spare so it was easier just to change it.

The repair panel then had its mounting holes cut as well as some MiG spot weld holes drilled. The panel was then painted with a combination of self-etch and weld-through primers and offered into place. This revealed the swage lines I created were almost, but not quite correct. Five minutes of hammer wielding had the edges lined up perfectly and ready for welding into place.

The final result was not too bad.


Finally, I ordered the rear valance repair section today, hopefully it'll arrive in time for an Easter weldathon!


27th May 2009

Well, needless to say the Easter weldathon didn't happen for several reasons, most of them out of my control! However, progress has been made. The rear valance repair panel, together with the two battery tray panels arrived from Metal Mickey in an ENORMOUS box, so big in fact that my 16 year old son was able to hide in it stood up and scare the living daylights out of my wife!

Initially the NS repair panel I fabricated earlier was fitted and then welded into place.


There was much pacing, pondering and drinking of tea before I could bring myself to cut the rear of the car off, eventually the cut off saw was pressed into service and the cutting started. All went well and after some fine tuning of the cut edges, the rear repair section fitted nicely. Before going any further the inside of the rear of the boot area which will be concealed by the repair panel was stripped, etch primed and seam sealed before welding the panel into place.


Next step was to fit the rear wings - again - to make sure the contours of the rear section of the wings matched the corresponding section of the new repair panel. Having established a good fit, the repair panel was tacked onto the inner wings from underneath. This upside down welding proved to be rather entertaining and involved a few small burns to head and hands and some singed hair, not recommended.

Next came removal of the rear wings for final welding of the repair panel to the inner wing panels and to the existing rear panel. Finally came re-fitting of the rear wings to make sure nothing has moved and all lined up properly. Success!

Next step was to remove the rear tub, stand it on the panels where the B post will someday be and replace the battery panel end pieces. I only had time to do one side as the sunny weather was beckoning me, that and the thought of taking the V8 for a spin. the thought of the V8 howling through the lanes was too much, so I packed up the welder and went out for a very satisfactory spin. hopefully I'll do the other side next weekend.


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