5 GT Turbo 11 years later silver bullet comes home

[Turbell]

Get in ! Most doubted you, I never.....
Buy a nice sharp new big file, it'll take high spots off without thinning surrounding panel.

 

[Norwich Nick]

Get in ! Most doubted you, I never.....
Buy a nice sharp new big file, it'll take high spots off without thinning surrounding panel.

Disappointed my childish side there by not using the files proper name, bastard, not you, the file

Good job there Duncan, you can do mine if you like

 

[Duncan Grier]

Got to love some synchronicity had completely forgotten to sort getting a 16amp extension cable only to find one jump out of the 'special buy section' at me while grabbing food before heading to garage



So finished spot / plug welding the sides of the cradle






Started to cut last patch.....next time

 

[Duncan Grier]

Another 90mins of progress but still progress

Got the last section of roof surround cut and welded in.......only cut the roof side side too much leaving a good 3mm gap just to test me while muttering choice words to myself lol

All ended fine and just need to tidy up



Turned attention to prep and spot welding screen which strangely still takes longer than you would think, however still resisted the urge to do a few in a row and blast of air and pause between



Hopefully finish off next time I get in

 

[Steve Swan]

Looking good...

 

[Duncan Grier]

With no time the last week odd due to work commitments with a day off today, grabbed a few hours this lunch

Finished prepping and spot welding last half along with plug welds, finished the few bits on the roof section, bridged the roof to cradle gap as I cut out it was not going to accept brass brazing (almost 5mm gap lol). Dressed plug welds and tidy of roof line....found a few more repairs needed and about ready for final check and some hydro80 and primer

The residual brass as expected reacted with steel but got a good tack on before bridging the gap and will inspect again but going nowhere.

Random pics of no particular order

 

[Duncan Grier]

Next also need to fix the pop section from damage to the roof gifted from cage work I paid for....never did get an offer to fix the damage done, correct the on the pish bits I had to do myself or any ££ back

So I am thinking drill a hole in the centre and weld it back up to shrink the metal.....welcome any views/advice?

With rot gone keen to not feck it up on this bit

 

[Steve Swan]

Another way would be to put a hollow dolly Like a big polo mint under the damaged area and use the pick hammer to punch the centre of the damaged area down and pulling it tight, then you need to fill it. You'll see the dimple on the inside though. An experienced old timer could heat shrink it by heating up the area and concentrating the heat into centre and gently hammering it to force the extra metal into the near molten spot in the centre. I have an old mate who used to be able to do this, was magical to watch, but really easy to completely F--ck it up, big time. Don't try it.

 

[Duncan Grier]

Thanks @Steve Swan, sounds like a less risk approach to my drill hole plug weld it to do the same thing

Definitely not going for that concentrated heat & hammer option as missing the key ingredients of skill and experience

 

[Duncan Grier]

Ok soooo

With very limited clearance in-between cage and roof made a basic diy pimple dolly....drilled hole, tested on bench with pick hammer with spare roof section which worked ok. Could not really get anything much wider or thicker in the gap.



While fine off the car the previous attempted repair on roof on closer inspection had a bit of a small hole/tear and metal very thin in the centre area even with slightest tap of hammer could tell it was not going to end well.

So I went to my plan A and got welder fired up and with a fictitious voice of @Steve Swan in my head making a mmmmnnnnn you sure you want to do that and not just move the dimple somewhere else

With a short blast as it cooled a distinctive pop noise.....followed by panic check was a bit better



Proceeded to get hands on with it and have a good feel mix of slight hammer and dolly and 3 more spots, flattened the welds with finger file and no more poppet....I would say 94% as it should but felt quit while ahead and once skim of filler and roof lining in not sure anyone would notice



I also got my flattened 22mm copper tube folded over and welded up the couple of holes that had not survived the plug welds, few more welds on lower mounting section and went looking for any minors....not torture you with more screen pics but ready for hydro80 and primer (forgot to wash brush last time so that's ruined lol)

 

[Steve Swan]

Quality. Always quit when you know you're ahead...

 

[Duncan Grier]

With this going well turned focus to a bit of a fresh review of what is left before back on table and or rotisserie and while the list is massively reduced I know the small simple jobs can take longer than some bigger stuff. Also reminded me I need to design some final resting places for stuff .

Good news is I think the inner arches do not need raising an inch as previously thought angle of pic makes it look offset but it sits centre in the arch



Decide to remove the below to make a bit of a small boot in the front or not, but thinking atm more hassle than worth for a small area and still need air intake setup for my oem heater/cooler/fan setup to have A/C hybrid and while might relocate could go retro on screen was reservoir also



This then got me thinking battery and for lower centre of gravity has a nice home here....spare old espace battery so would be smaller

 

[andybond]

fictitious voice

Do you do that as well? Everyone on here has a "voice" when I read the post.

 

[Steve Swan]

If we are getting to choose how we should sound as a voice in somebody's head, I would like to sound like Simon Pegg's version of Chief Engineer Montgomery Scott. If I give her any more she'll blow.......

 

[DaveL485]

I would like to sound like Simon Pegg's version of Chief Engineer Montgomery Scott.

Pretty much how you sound in my head save a little older/mature. Like, the age of the original scottie sorta thing (no offence )

 

[Leigh5t]

Top work. Its a monster project and you’re making good progress.

 

[Duncan Grier]

Time to start fixing the collection of random holes and or rust sections

Tonights blast, usual approach however welder did not like the magnet holding so gave up and just held it and fine




Plug welded the 3 holes using copper behind and then did my easter egg patch tidied up and gave front lick of hydro80