Kev's workshop projects

Crank
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Re: Kev's workshop projects

Post by Crank »

Has anyone ever taken on a restoration that required less work than was anticipated?
Your a real inspiration Kev. Reading your posts, and others, motivates me to get back into the garage.
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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Glad it's appreciated mate, I do still wonder if it's madness or bloody mindedness or just plain stupidity but I do like the underdog...
So much so I've just done a deal to get my old Y10 GTie back off Richard, it'll be getting the same treatment in the future..
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Re: Kev's workshop projects

Post by KevJTD »

Passenger side all welded up now, happy with the outcome.
IMG_20200912_172453.jpg
Fitment around the light is decent.
IMG_20200912_172604.jpg
Onto the other side now, pretty much identical amount of work needed so as I've done one side now then it's easier second time as you know what needs chopping out and where..
IMG_20200912_190108.jpg
Hey presto! :lol:
IMG_20200912_200156.jpg
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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Bumper bracket reinforcer had more rot at the top end than I'd like, especially as this side bracket is also the towing eye, so a new top half will be made.
IMG_20200912_200231.jpg
Underside has some surface rust which the electrolysis method will sort out.
IMG_20200912_200237.jpg
Should be able to get 3 full days on the car next week so I need my arse kicking if this side isn't done and I'm chopping the windscreen surround out..
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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Good news on the windscreen is Autoglass have got me one on order and can do it through my insurance once I'm ready for it.
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junior
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Re: Kev's workshop projects

Post by junior »

KevJTD wrote:
Sat Sep 12, 2020 10:32 pm
Good news on the windscreen is Autoglass have got me one on order and can do it through my insurance once I'm ready for it.
That is good news. Nice to have someone take an awkward job off you, I would think. Hope it turns out well.

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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Made a start on the drivers rear quarter today, had to dig through the same amount of layers as the other side before finding solid steel again. But I got there.
Repaired the reinforcer bracket as before, then made and fitted a new inner lower repair section.
IMG_20200915_144820.jpg
The bumper bracket wasn't so good as I mentioned before, only the bottom half was salvageable but at least that was the important bit.
IMG_20200915_144810.jpg
Made up some strong sections and spot welded before seam welding them together, this side is also for the towing eye so needs to be strong..
IMG_20200915_175330.jpg
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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Had time then to make up the outer skin, curved at the bottom as before using the same cardboard template.
IMG_20200915_194333.jpg
IMG_20200915_194350.jpg
Alignment gained using the rear light unit which after all is what needs to be right.
IMG_20200915_194133.jpg
Got tomorrow on the car so I'll make up the inner sections before the outer gets welded into place.
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Re: Kev's workshop projects

Post by KevJTD »

Inner section repaired, which again was a bit awkward as you need to make a section blind, behind the outer section so it kept having to be taken off and gradually make the inner bits.

Eventually though it all lined up so once that was welded into place the outer skin could go on.
IMG_20200916_165845.jpg
Trial fitting of the bumper and lights came as a relief that it all lined up just nice! All the measuring and template making paid off.
IMG_20200916_172326.jpg
IMG_20200916_172158.jpg
IMG_20200916_172151.jpg
Next visit I get to start the windscreen surround repairs... Should be nice!
Actually it shouldn't be too bad a problem, apart from the section with the vents in, hoping that doesn't stretch down the "fingers"..
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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Lowered the car down a bit now so I can get at the windscreen surround.
Trying to figure out how to make a repair section where the vents are, tried a few ideas but none successful enough, have come up with a new plan to make another jig.. Another time.
IMG_20200912_175239.jpg
With that in hand I started on the easier section, relatively speaking. The 'screen flange section curves in a couple of directions so not a simple folded repair as it all needed to be shaped so more sections to allow for manipulation.
Looked a bit grotty even before the' screen came out. I'd put some silicon in there in an attempt to keep rainwater at bay..
IMG_20200909_163519.jpg
Section of rusty bit cut away, new repair piece awaiting welding.
IMG_20200918_143845.jpg
Then infill the triangular hole and a bit around the bottom corner, that's one section done!
IMG_20200918_154322.jpg
IMG_20200918_183257.jpg
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Sud 145
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Re: Kev's workshop projects

Post by Sud 145 »

loverly jubbly. Nice work Kev, can see this wanting on my Sud as maybe mentioned b4.

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Re: Kev's workshop projects

Post by KevJTD »

If there's any sign of rust, or even bubbling paint mate it'll be as bad I'm afraid.
All sortable though 8-)
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Alfastrut
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Re: Kev's workshop projects

Post by Alfastrut »

Nice work Kev. I really need to get my screen out and just get on with it. It's the last bit of welding I need to do before it gets a respray

alfadave
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Re: Kev's workshop projects

Post by alfadave »

Just get rid of the LH vent altogether (some paint runs there?)

The RH one looks ok.

Passenger can open the LH window for ventilation!

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Re: Kev's workshop projects

Post by KevJTD »

That did occur to me Dave :lol:

Yes, it's had paint before, it best get used to having the runs :lol:
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alfadave
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Re: Kev's workshop projects

Post by alfadave »

In fact, get rid of both vents to even it up!

Air will get to the heater somehow.

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Re: Kev's workshop projects

Post by KevJTD »

alfadave wrote:
Sun Sep 20, 2020 8:40 am
In fact, get rid of both vents to even it up!

Air will get to the heater somehow.
Nice idea in a way, would stop rainwater getting in, but also it would most likely force air for the heater to be drawn in from the engine bay which is far from ideal.. Sleepy time :lol:
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Re: Kev's workshop projects

Post by KevJTD »

Started on my trip around the windscreen surround today, drivers side pillar first job.

Most of it cleaned up pretty well, knotted wheel and grit blaster did most of the work. Small bits to weld so a decent result really.
IMG_20200921_164752.jpg
All welded up, loving my spot welder 8-)
IMG_20200921_175801.jpg
Top section was god all the way across after all the cleaning, bingo :D
IMG_20200921_175808.jpg
Passenger pillar wasn't too bad, just a couple of bits needed welding.


IMG_20200921_145917.jpg
Just the passneger bottom corner then the bit around the vent...
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Kegsti66
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Re: Kev's workshop projects

Post by Kegsti66 »

Coming together mate.
Could you cut the vents out of another car or bonnet that look similar?

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Re: Kev's workshop projects

Post by KevJTD »

I did consider going around the local scrapyard with a saw.. :lol:
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Re: Kev's workshop projects

Post by alfadave »

Run some fresh air to the heater with ducts from the inner wing area?

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Re: Kev's workshop projects

Post by KevJTD »

I'd tried making a jig to make a section with the slots, almost works and on reflection I know how I could make it work by trapping the steel between two jigs rather than trying to form it using just an underneath jig..

All academic now, had to grow a pair and just get on with it
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Re: Kev's workshop projects

Post by KevJTD »

Cleaned the panel back as far as I dared whilst keeping the shape of the vents, thankfully the rust stopped short of going in the curves but didn't leave a lot of material to weld to.
Plate made up with the necessary curves to follow the curved screen flange in both directions, not easy in a patch that is folded twice as the central piece needed to curve, but it got manipulated enough in the end.
Then the shape cut to match the remaining piece of bulkhead..
IMG_20200923_160025.jpg
Welding was very gently done in small dabs, overlaid to allow it to melt down into the joint.
IMG_20200923_161850.jpg
Equally careful grinding back as all too easy to take away the surrounding material, thin areas got re-welded.
IMG_20200923_170948.jpg
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Lancia Delta integrale
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Re: Kev's workshop projects

Post by KevJTD »

With the hard bit done the rest was straightforward enough, curved corner needed care to keep the shape so the new screen will fit..
IMG_20200923_203756.jpg

Friday I'll make a start on the drivers door, the last bit of welding... 8-)
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Lancia Delta integrale
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Re: Kev's workshop projects

Post by KevJTD »

Drivers door had a scab on the outside and some rust on the bottom plate, nothing too serious you'd think :roll:
IMG_20200928_220730.jpg
IMG_20200928_220809.jpg
On looking inside the door though it was clear the bottom plate rust carried on into the seam, the outer section peeled back confirmed that..
IMG_20200925_114444.jpg
Nothing for it but to cut the full length of the outer skin off.
IMG_20200925_151637.jpg
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Lancia Delta integrale
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Lancia Dedra turbo
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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

Bottom plate repaired including further around the forward edge up towards the door card aperture.
IMG_20200928_133850.jpg
Then the new outer skin repair being lined up with the door and wing back on the car so it can be fitted in the correct place, located with clico fasteners so when the door comes off for fitting the plate the location is easily repeated.
IMG_20200928_175700.jpg
All welded into place to the skin and folded with sealant along the bottom edge.
IMG_20200928_222052.jpg
IMG_20200928_222128.jpg
Getting to the point where the welder can have a rest now, think there's a bit on the hatch but that's the last...
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justsuds
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Re: Kev's workshop projects

Post by justsuds »

Looks good Kev, - how do you weld the full length of the door without it buckling ??
John.

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Re: Kev's workshop projects

Post by KevJTD »

justsuds wrote:
Tue Sep 29, 2020 10:27 am
Looks good Kev, - how do you weld the full length of the door without it buckling ??
John.
I dont'! It distorts even just using small tacks, just have to accept it and try and straighten it out as best you can.
On the fabrication course I went on a few years back I asked the guy how he'd stop distortion when doing door bottom repairs. He answered by saying he wouldn't ever repair a door bottom as distortion is impossible to prevent, he would make a whole new door skin instead!
One solution pointed out to me by my friend Chris whose Dad restores Capris' is to use a spot welder on the joggled flange which I agreed would be much more resistant to warping and potentially a stronger join as appose to welding one edge. I need to get some different arms for mine to allow cranked finger type arms to get into the tight spaces.
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rsfruitbat
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Re: Kev's workshop projects

Post by rsfruitbat »

Hi Kev
Brilliant work as always Kev.
I was wondering what the right sequence is to cover freshly welded areas.
Zinc primer, seam sealer, stonechip, paint, or something else, or what would you swap round / exchange.

Rsfruitbat

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KevJTD
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Re: Kev's workshop projects

Post by KevJTD »

My method, which I am not saying is gospel just what I do, is once something is welded it needs to be coated ASAP as a freshly welded joint will rust in hours.
Etch primer is good but red oxide or similar works well enough, make sure the surfaces are roughed up so it will stick, shiny surfaces will let the paint flake off.
After that the inner surface really needs to be seam sealed if reachable to prevent moisture getting in through any pin holes in the weld joint, or if access isn't possible then I use stoneguard which will do a good job at sealing it.
Outside face of the weld I put a thin layer of fibre glass filler as its waterproof before using regular body filler for shaping.
Important bit is preventing moisture getting into the repair in the future.
Giulietta JTD 170
Lancia Delta integrale
Lancia Flavia coupe 1.8 1963
Lancia Dedra turbo
Renault Clio 197 RS

I'm bad with people things
But I should have tried more

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