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Author Topic: Y10 boot corner rust  (Read 3461 times)
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stanley sweet
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« Reply #15 on: 25 May, 2018, 02:26:05 PM »

That's impressive!
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1971 Fulvia 1.3S 'Leggera'  1999 Lancia Lybra 1.9JTD LX SW
DavidLaver
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« Reply #16 on: 25 May, 2018, 02:46:15 PM »


I like the way the surface rolls into the big square hole.
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David Laver, Lewisham.
frankxhv773t
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« Reply #17 on: 29 May, 2018, 06:20:00 PM »

My late best man gave me a joddler when he gave up working on cars. The head just fits through the square hole so I was able to run round with that to make the flange. I suspect it's important to the rigidity of the panel.
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DavidLaver
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« Reply #18 on: 29 May, 2018, 10:54:27 PM »


I spotted the joddler in the photo under the jigsaw. 

https://www.frost.co.uk/joggler-joddler-flanger-with-hole-punch.html

Never ocured to me, but the ones with the hole punch, is that a size for plug welds or a self tapper?

The one bit I'm jealous of / interested in / look occasionally at is the "railway track anvil".  Its obviously handy enough to bring out with everything else...  They vary in price, and obviously to have one delivered is a fortune.

https://www.ebay.co.uk/itm/Anvil-Train-Track-Rail-Black-Smith-200mm-long-cash-on-collection/132640517307?hash=item1ee1fdacbb:g:0ycAAOSw3zNalDyI

https://www.ebay.co.uk/itm/Vintage-Iron-Railroad-Railway-Line-Bullhead-Rail-Track-Hobby-Anvil-Railwayana/302746292571?hash=item467d15d15b:g:eUoAAOSwWFFbA~G6


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David Laver, Lewisham.
frankxhv773t
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« Reply #19 on: 30 May, 2018, 05:53:31 PM »

The hole punch in the joddler is for plug welds which, after the link about welds for MOTs, I shall be using later in the project.

My rail track anvil was acquired from a blacksmith at a re-enactors fair but they don't turn up very often. It was surprisingly expensive for a couple of inches of scrap steel but is infinitely more convenient than carting my 1/4 size anvil to events.
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frankxhv773t
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« Reply #20 on: 01 June, 2018, 07:08:14 PM »

The replacement bumper bracket mount has had reinforcing plates fitted to bridge the gap where it folds outwards and captive nuts welded in for the bumper bracket to bolt into. The first cut has been made on the off side to reveal the extent of the internal rot which actually isn't too bad on the inner arch. I have included a pre dismantling picture of this area to show how hidden the problem was. Also there is a close-up of the Joddler for David.


* bumper bracket completed.JPG (130.25 KB, 720x480 - viewed 104 times.)

* OSR pre dismantling.jpg (111.9 KB, 854x480 - viewed 70 times.)

* OSR outer panel cut away.JPG (65.72 KB, 720x480 - viewed 117 times.)

* OSR extent of rot.JPG (70.71 KB, 720x480 - viewed 105 times.)

* Joddler for David.JPG (145.84 KB, 720x480 - viewed 109 times.)
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frankxhv773t
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« Reply #21 on: 04 June, 2018, 06:29:16 PM »

The NSR bumper bracket is in place and the NSR inside corner is complete and primed. It isn't the prettiest job in the world but hopefully things will improve with practice. Cutting away the OSR corner has started cautiously. There are five layers of steel in this cunningly designed rust trap. I have remover the remains of the top part of the bumper bracket and plan to try patching the least damaged parts in situ this time to maintain better reference points for reconstruction.


* NSR bumper bracket 4 (Small).jpg (45.89 KB, 480x480 - viewed 99 times.)

* NSR internal primed (Small).jpg (40.43 KB, 480x480 - viewed 101 times.)

* OSR corner showing all the layers 1 (Small).jpg (49.06 KB, 480x480 - viewed 100 times.)

* OSR bumper bracket part removed (Small).jpg (46.72 KB, 480x480 - viewed 101 times.)
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DavidLaver
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« Reply #22 on: 04 June, 2018, 08:38:13 PM »


Looks good from here.

Certainly looks BETTER Smiley

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David Laver, Lewisham.
lancianut666
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Slow but rough


« Reply #23 on: 04 June, 2018, 09:06:31 PM »

Hi Frank
where did you source the back exhaust box?
Clarkey
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Fulvia Coupe S2 Flavia Coupe 1967 1.8 Kugelfischer Prisma 1.6 carb Y10 Fila Y10 Touring Dedra 1.8 Dedra 2.0 Turbo Appia S1
frankxhv773t
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« Reply #24 on: 05 June, 2018, 09:21:20 PM »

I expect the back box came from Halfords as I have a trade card that makes parts quite reasonably priced.

Today I plated the OSR outer panel and got a coat of paint on it. All this will be covered by the rear light so the finish doesn't matter too much.


* OSR outer corner plated and primed (Small).jpg (53.26 KB, 480x480 - viewed 88 times.)
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DavidLaver
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« Reply #25 on: 06 June, 2018, 11:06:40 AM »


Is this the bit you didn't want to weld?   

What was the decision on that?  One approach might be to weld it, but forgive yourself whatever thickness of filler it took to make look reasonable.  Then again you might distort the whole panel and have problems elsewhere...  Alas I don't have the experience to know.

http://www.mig-welding.co.uk/thin-metal.htm

Have also seen it done as tacks, then fill in between the tacks, then in between again and again until its continuous.

http://www.mig-welding.co.uk/removing-floor.htm

"Distortion is always a risk when welding a long seam on a flat sheet. Distortion is caused by heat build up in the panel, so the way to reduce distortion is to weld small areas at a time and allow the area time to cool before doing any more welding nearby.

A 1 inch seam was made 1/3 of the way along the floor, then a second further along the floor. Further seams were welded between those seams and so on until the the joint was fully welded. A complete seam probably took around half a day, allowing plenty of time along the way for everything to keep cool
."
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David Laver, Lewisham.
DavidLaver
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« Reply #26 on: 06 June, 2018, 11:11:14 AM »

https://www.youtube.com/watch?v=hNcOGbDbDK4
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David Laver, Lewisham.
fay66
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« Reply #27 on: 06 June, 2018, 02:03:16 PM »

Many modern cars are constructed using industrial adhesives, if you have had to joggle the panel why not stick it together and finish with filler when panel is prepared for painting
Can't see why you can't, but not on load bearing structures?
Brian
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Own 1966 Fulvia 2C Berlina since 1997, back on road 11-1999.Known as "Fay"
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frankxhv773t
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« Reply #28 on: 06 June, 2018, 06:34:57 PM »

Following David Lavers' post on 24th May It seemed the MOT requirement is for seam welds where a panel has been cut into and spot welds where panels were originally spot welded. As a result I seam welded in the new metal and plug welded where it overlaps the rear panel.


* OSR corner plated (Small).jpg (53.22 KB, 480x480 - viewed 73 times.)
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DavidLaver
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« Reply #29 on: 07 June, 2018, 07:50:47 AM »


I think the MOT requirements are within "proscribed areas" - near suspension and seat belt mounts, I'd assume also engine mounts. 

For bodywork - while not best practice - am sure most LMC members will have come across the "self tappers and wodge it full of filler" technique.
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David Laver, Lewisham.
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