So its Sunday morning and I have decided to have a go at repairing the bulk head which someone has decided to cut a piece out of and drill lots of holes in it!
I was going to just swap the bulkhead out of the Campus but decided against it. I got a piece of scrap tin and began bending it into shape by hand.
I noticed the little diagonal section that was missing so I left it long and cut it to suit!
My thinking was to get it close enough and then hammer and weld it in position! I've recently starting using a metal dolly to hammer the welds against, it seems to work quite well!
I tacked it in and then fully welded it once I was happy with the shape
The welding is not pretty, but it has full penetration and I am going to grind it down!
I then got the snips and trimmed it back to suit.
I turned out better than I expected it too.. Then on to the holes.. This is where things went south!!
I had welded in some of the holes last week but hadn't gotten around to grinding them out, so I got busy with the grinder, but got a bit over zealous with it and ended up making absolute shite of it!! I ended up having to cut a patch out in the end!
So I got busy with the hammer, cold chisel and a piece of scrap steel tube to form this shape!
It looks ok!
I then tweaked it some more and then welded it in! I gave the weld a bit of a hammer with the dolly behind it and knocked it further into shape!
I gave it a grind off!!
So that balls up cost me nearly 2 hours!!
Then the wife shows up and starts f*****g about!!
After she got bored and f****d off, I got on with welding the other holes and grinding them down, I almost messed that up too and had to go back on a few patches where I came through with the grinder! Overall I am please with how it turned out!
I then decided that the front bumper mount on the drivers side needed replacing with one like I fitted on the passenger side, so I made a replacement plate.
I cut the old one off and welded the new one on!
I then welded in the new front bumper mount and ground it all down!
I then dropped some etch primer on it as a temporary measure!
I then had a clean up and put the car away and went for dinner. Aparently the sun is out today!!
Whilst eating dinner I was thinking how black the rust treatment was on the back underside of the car so went to have a look after dinner. I got the pointed hammer out for a quick investigation!
A couple of gentle taps and the holes begin to appear!!
So I got the car up on a stool and bottle jack, ratchet strapped it to the roll over frame and removed the tie from the rollover jig.
I started to drill out the spot welds to remove the rear towing eye, or at least thats what I think it is!! But my last bloody spot weld drill bit broke!!!!
So I am calling on the expertise on the forum on how best to deal with this rust on the rear legs. My idea is to remove the attached bits and then cut the leg back as far as good metal, make a new piece, weld it in and then clean up and re-attach the towing eye etc.
@DaveL485 &
@Big Steve - Raider what do you suggest with this?
Thanks for reading guys!
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