1992 Merit Plus - here we go again!

[kevw]

Let me know Scott

[kevw]

Got a couple of days off work so spent a few hours at the unit today.

Got all this mud:



Out of here:



Chopped a bit more off the outer arch:



It'd had this patch put in but hadn't been welded to anything! Tonnes of seam sealer holding it in! The sealer was also creating a water trap, I've always made sure the water can run away when I seal stuff up.



Messed about chopping the outer repair panel down and then cut away the rust from the inner arch.



Pushed the repair panel into the arch to have a look. Probably going to trim the panel to the size of the hole and fit it flush rather than with a lip:

[kevw]

My MIG keeps jamming. All I managed to do today was fit the inner arch repair panel. I hoped I would have had the outer one welded on too:

[Rickyb]

Ive just read this from the start, looks a mint project keep up the good work.
Rick

[kevw]

Ive just read this from the start, looks a mint project keep up the good work.
Rick

Cheers mate, lots to do but it should be a nice solid, straight and clean car when done

[Iain]

Instead of butt welding the repair panel you could look at getting a joggler tool. Nice work going to be a good repair when done

[kevw]

Instead of butt welding the repair panel you could look at getting a joggler tool. Nice work going to be a good repair when done

Just had a look at joggling tools. Seem to be about £45. Might be worth getting one. Good call.

[kevw]

Still not got a joggling tool. Need to order one.

Found that the rot or even the poor repair behind the fuel filler had lead to rot inside the sill:


This was after picking but before cutting as above:


Checking clearance of the arch, I've folded the lip and will fold the outer lip too so there's plenty of room:

[kevw]

Knocked up a patch before leaving for the day:

[Benn]

Very minty looking wheels.... Good work on the de-rusting.