PHU41R Restoration - part 9 - first body repairs

[iRS]

This is continued from: viewtopic.php?f=45&t=12323#p66978

Once stripped, I counted up about a dozen areas needing welding, ranging from major things such as the floors, to much smaller repairs. I thought I'd start at the front, so tackled the corrosion between the shock absorber mounting strengthener piece and the inner wing. This didn't look too bad on the passenger side:

However, a bit of cutting revealed this:

I tidied that up by cutting out the worst area:

[iRS]

and then welded in thick gauge steel to repair the strengthener:

and then finished it off with standard gauge steel

It needs a bit of tidying up still, but now its rot free.

[iRS]

On the driver's sides repair had already been made. I thought about grinding off the weld and making it look better, but then I thought again and removed the repair piece:

That revealed this:

and with the worst cut out:

[davidr]

good stuff Roger - keep it coming!

[J44EAG]

Moths. Definitely moths.... trust me. I know about these things.

Mike.

[iRS]

Its taken me ages to get around to finishing this off.

First I thought cardboard:

Then I thought metal:

I think the metal may last longer......


Fabricating the metal was actually really quite tricky due to the numerous folds and bends in the piece. I ended making it out of two pieces and welding up one of the fold lines.