1987 3.2 Carrera Backdate project - Sladeys hotrod

[sladey]

Then trying the patch for size

Looks OK from this side




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[sladey]

But from this side it’s shite



That flange should sit on top of the bit underneath


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[sladey]

I knew I couldn’t work that piece any more so I cut the flange off and trimmed it down to fit

Then tacked it in place




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[sladey]

And welded it up - the whole piece fits properly now




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[sladey]

Welded it all in



I smoothed it all down a bit after this but not completely - it’s all hidden


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[sladey]

And finally a coat of epoxy mastic




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[sladey]

Before finishing I started on the lower bit - the ‘letterbox’

Initially I was planning on drilling out the spot welds. However the metal appeared to be 2-3 mm thick!! Eventually resorted to a cutting disc so I could at least make a start



This side of the chassis rail seems to be multiple layers - at least 2 and maybe 3 in places. This is where the impact bumper mounts used to go.

Any suggestions on the thickness of steel to go back in there?


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[sladey]

Good stuff Mark,
I've taken to removing tiny patch of 'weld through' primer from behind the the plug weld. Splatter central otherwise!

I’ve been doing the same - once I’d got it clamped in place I scraped it aware with a screwdriver


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[Gary71]

It may have changed on the impact bumper cars (there’s a clue there!) but nothing on my car was thicker than 1.2mm in that area.

Anything more than 2mm will be so hard to hand work it’s not worth it. As your car is now ‘early’ it maybe ok to backdate the strength as well.

[sladey]

Thanks Gary

[sladey]

OK time for another update. I’ve generally managed half a day on it each week-end. Progress is fairly slow but I’m happy that each stage is being done thoroughly.

I’m 2 months down the road now though and still haven’t got onto the small rust bleb that was going to take a week-end in early January.....

So anyway letterbox time:-

Out with the CAD




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[sladey]

Leading to this to help bend the right shape




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[sladey]

Which produced this piece




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[sladey]

Which welded in OK



I had to put the bumper back into place to work out where the mounting bolt holes were to go


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[sladey]

Once the position was established I was able to weld captive nuts in place




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