Curved Metal Fabrication and Welding Blog

Tell us your ongoing tales and experiences with your French car here. Post pictures of your car here as well.

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Pug_XUD_KeenAmateur
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Re: Curved Metal Fabrication

Post by Pug_XUD_KeenAmateur » 15 Jul 2018, 17:27

Thanks Gibbo, I'll be doing that.

Meanwhile, its a lot worse than I thought, which is incredibly frustrating, I've made measurements from 'Zero Points' that are now useless and cut down my replacement section (that's going to have to be welded back to its original size). I might even have to chop out some of the inner cill.

Its all possible and I've got all the repair sections, but suddenly the job's got a whole lot bigger; should've known really.

Perhaps one of the Admins can change the title of this to 'Welding Blog' or similar, might need moving elsewhere on the boards, too
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Re: Curved Metal Fabrication and Welding Blog

Post by white exec » 15 Jul 2018, 22:54

Diesel will separate from water of its own accord. If left standing, the water will simply sink to the bottom. This is what happens in a diesel fuel filter, where there is a water-sensor and drain-off point at the bottom.

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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 17 Jul 2018, 19:05

After a day off from it yesterday, things are going better.

I've cut myself a new Heat-Sink, from what had once been a shower cubicle

and then having spent ages cleaning up the edges of the now too small replacement Outer Cill, always a long-winded & laborious task; welding it back together went pretty well, despite the enormous 1.3mm chasm which represents the loss in cutting.

Obviously, I shall be 'joining the Dots' for a continuous seam weld at a later point; but I'm happy with that for now. It'll need shortening in length and a lower flange adding at a future point.

I moved on to cutting off more of the forward section of outer cill. Thankfully I only needed to remove a further 50mm approx to get to good sub-structure, and also cutting a further similar amount from the top (no pic).

A Cardboard Template to represent the Outer has been made while the sub-structure's in place, but most of that will be going tomorrow.
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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 19 Jul 2018, 20:18

so its all change since the last posts.

The idea of using an Outer Cill comprised of at least three different pieces of metal, with a welded 'chasm' that simply can't be as little as the 1.3mm I suggested in the previous post, seemed faintly ridiculous, for the sake of a 'Step' in the panel....

...thankfully, after just a short period of experimentation its clear that the step can easily be removed from the tail end of the good outer cill, where it will meet the new metal; and this therefore permits the use of a simple piece of 0.9 galv sheet

I don't actually have a sufficiently large piece of steel as yet, but that'll probably arrive tomorrow; but the hole where the Cardboard Template for the Outer Cill has been enlarged.

There's been quite a lot of 'making and enlarging of templates', as the extent of the rot requires; which has been the source of some irritation but I'm mindful that when I did the opposite side 18months ago, I had a much more relaxed approach to templates and zero points, and paid dearly for it; hopefully not going there again.

Templates have been made for 'the one I made earlier' Curved piece, the Sub-structure and the Inner Wheelarch section, all of which have been now been chopped out, so the grounds are pretty much ready for welding.

I did consider removing the Inner section, which would expose the Fuel Tank and Brake Pipes to view. I have a spare section, but that feels like going too far and my spare section isn't perfect either, so I've cleaned it up and bar a further pass or two with my various rust removal rotary tools, it'll be staying like that.

I've also so far got away with leaving the fuel tank in situ, and its likely that with appropriate protection I can leave it be, so that's played a part in my decision too.

I noted that the date thingummy on the Fuel Tank is in line with other parts on the car, albeit a little later, its stamped 1995, Week 27; where other fittings are generally labelled Jun 95, so it would appear to have been manufactured in early July, I'd guess the factory wouldn't want too many 16 Gallon fuel tanks taking up space so they'd be more likely than an Instrument panel, for instance, to be fitted promptly following manufacture. It was reg'd in Dec that year.

Less pleasingly, I note that once again the Brake Compensator Spring has fallen out of its housing and is dangling uselessly, a fiddly thing to refit, but I found last time that cable ties at either end of it will assist

and that the 'Turret' over the rear suspension bump stop is in desperate need of attention from my welder. I shall see how keen I'm feeling when its all back together.

Timescale is going well so far, we're up to about 6/7 days work and over half way, so that's reasonably satisfying too.

Oh... and for the first time in my ownership, its now on Axle Stands front & rear. I was a touch concerned about putting excessive load on the nearly new NSF front tyre while it was on just one stand, hence the stands

...and apologies fort the quality of the fourth pic, it was a bit over-exposed and my 'corrections' with Faststone haven't made it a thing of beauty.

Hard to believe all this palaver over what started out as a tiny patch of rust in the Wheelarch and some bubbling on the tail end of the Outer Cill.
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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 20 Jul 2018, 19:28

shh! Its going well so far.

The screen has been modified with the Sewing Machine and is now much simpler and just as effective

My broken Music Stand was easily fixed, its been waiting since winter, til I've got the welding gear out

A repair to my mate's Pointing Trowel didn't work, but I wasn't hopeful, its more a Brazing job really.

The metal turned up by post before I ran out of bits & pieces to get on with

The first and most complicated of the panels has been made to template and fits really well
...and the second panel is well underway.

Would've preferred it rather less hot today, but you can't have it all.

I'm feeling like I'm 'on the Home Straight now' and feeling well happy about it. Projected maybe 4-5 days work remaining and a total spend of about £50, which includes a number of small tools / consumables, Gas, Wire and Metal. A couple of celebratory Beers this evening and a day off from it tomorrow!

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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 21 Jul 2018, 17:14

well, so much for the day off. I was up a little earlier than usual, the weather felt cool and the forecast was for today not to be as hot as the next few days, so the day off has been 'shunted' to Sunday.

I've remade the sub-structure to a good standard, having changed my mind about using the secondhand bit that I've had a while

The Inner Wheelarch section is made & ready to go

The less than wonderful inner cill has been cleaned up to a reasonable standard and Kurusted where I won't be wanting to weld it

All the joints have been cleaned both sides and painted with XC-90 Weld Thru paint

And the Outer Cill section is well on its way.

Next up is temporary fixings
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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 23 Jul 2018, 18:40

Getting there....

Inner wheelarch section in place (except for the non-standard 'return' on the bottom) and Sub-Structure tacked in place at the top, the fold at the bottom's not right yet.

The original sub-structure had a fold in it at the rear, but saw no reason to keep this, hence cutting it off more or less flush with the wheelarch section
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Re: Curved Metal Fabrication and Welding Blog

Post by Hell Razor5543 » 23 Jul 2018, 23:01

Sometimes there are strange 'kinks' in the hidden metalwork of a car to help eliminate unforeseen harmonics.

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Re: Curved Metal Fabrication and Welding Blog

Post by Zelandeth » 24 Jul 2018, 11:09

That looks to be coming together nicely now.

Definitely a totally different level to anything I've achieved so far!

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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 24 Jul 2018, 12:55

I'm not working out there this afternoon in this heat, I did yesterday, but doing so is some kind of madness.

Some progress today anyway though, sub-structure welded in properly and bent to curve

and the curve piece this thread started with cut to size to fit.

There's always a 'compromise' when cutting metal to template, between trusting your template, cutting it 'tight' and risking ruining it and faffing at length filing and grinding; I tend to go for the latter.

Keep at it Zel, if you need to, welding's not the easiest thing in the world to do, but like so many other things once you've got 'the Knack', then it comes. Maybe some day we'll exchange skills, your electrical & soldering, my welding. I very much doubt my skills overall are a match for yours.

Inspired by Mr Razor's comment, and my own 'afternoon off' due to the weather
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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 30 Jul 2018, 20:08

nearly ready to go (obviously some trimming required), the end is in sight!

...only another three at least welding jobs on the prioritised list behind this one !
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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 02 Aug 2018, 16:38

Job's a Good-Un, at last

Haven taken a little over 300 photos in the end, I really could've made more of an effort to photograph the fitted Outer Cill before I slapped first some Waxoyl / Hammerite compound on it, which is what the brown mark is.

...but I didn't. I was just keen to be getting on and finished.

All of it done in the street, using a makeshift screen for some processes, eg welding.
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Re: Curved Metal Fabrication and Welding Blog

Post by Zelandeth » 05 Aug 2018, 00:20

Looking good! Well done on persevering with that.

Sorry for sounding picky...but they're sills, not cills.

Sorry...my mother was a librarian and part time English teacher, I can't help it that things like that make my teeth itch!

My idiotic spelling pickiness aside, really good write up of the whole process. A real inspiration to see what you can do with some good old fashioned determination, even without a fully equipped workshop in sight.

Thanks for keeping at it and sharing with us.

I really need to get around to doing the write up for the Lada injection project properly...I took well over 500 photos during the process...I probably need 10% of them.

Hope you enjoy getting to drive the car again now!

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Re: Curved Metal Fabrication and Welding Blog

Post by Pug_XUD_KeenAmateur » 05 Aug 2018, 13:06

well, well, well; I had to check you was right on that one Zel, coz for a moment there; I disagreed, but no; Sills with an 'S'. I like to be 'proper' with spelling too, so thanks for that.

....albeit I know I can be sloppy with my posts here, my fingers type faster than my brain works; which for hand-writing purposes makes for the most appalling scrawl.

Confusing Bought and Brought winds me up ('er indoors does it frequently) as do Americanisms like OrganiZe.

Thanks for the enthusiasm and encouragement, it did help me keep going and after the sad (but understandable) loss of some high profile contributors here, I think its nice for everyone to make every effort to keep the Forum Alive & Well.

Definitely enjoying it again thanks, its been out every day since I put it back on its wheels on Weds, clocking up about 80miles so far. Today's a 'rest day' but I'm instead loading it up for a multi-purpose trip tomorrow; hoping not to get it dirty coz it was vacuumed at the end of all the work, but me & cleanliness don't go together!

...talking of which, if anyone's ever had trouble with their Dyson, what a fabulous piece of engineering they are. Our DC-07 gave trouble recently: one large Screwdriver to change the Brush Bar and no tools required whatsoever to change the filter; combined cost just north of £8, time about 1/2 hour.

About 10% of the 500 'Lada Injection' photos sounds about right, I've made copies of 15 'key' photos from my Welding 300, but I'll be keeping em all as I'm sure you will.

I wouldn't be at all surprised if you've catalogued yours similarly to this.... ie, with appropriate filenames.
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Re: Curved Metal Fabrication and Welding Blog

Post by Hell Razor5543 » 05 Aug 2018, 17:26

On the canals the 'step' that the upper gates rest on is called the 'cill'.