baaaaahahahaha thats baxter worthy bodging
Printable View
baaaaahahahaha thats baxter worthy bodging
it all had to go!
Heres a pic of the new panel from Hadrian panels (full sill was £25 inc delivery) offered up to checl for fit...
http://www.modelnovas.com/images/passill24.JPG
Needs a little fettling just on the edges but overall its an excellent fit and lines up with whats left of the original jack piunts really well
http://www.modelnovas.com/images/passill25.JPG
http://www.modelnovas.com/images/passill26.JPG
I then ground down the paint to reveal the spot welds. The new sill will be "plug welded" to where the prev spot werlds were to replicate the fit and the edges that bond to the existing panels will be seam welded. The old welds need drilling out 1st
http://www.modelnovas.com/images/passill28.JPG
The bottom edge of the sill was so rotten I only needed to drill out a couple of welds - the rest just knocked out with a hammer and chisel!
http://www.modelnovas.com/images/passill30.JPG
I then marked up guide lines to where the new panel would go so I could cut the old one out - I left 10mm extra just incase and also to allow for some "lap welding" on the straight sections for added strength
http://www.modelnovas.com/images/passill31.JPG
I then cut the passenger sill off and was confronted with this right next to the passenger seatbelt mounting point!
http://www.modelnovas.com/images/passill32.JPG
http://www.modelnovas.com/images/passill33.JPG
http://www.modelnovas.com/images/passill34.JPG
I removed the wood (which was well and triely secure!) and cleaned up the edges
http://www.modelnovas.com/images/passill36.JPG
well at least that wood be the only part of that Nova body that won't rust. Shocking! Great work though
ade, please keep the wood for the first lighting of the loonaque at the national weekend
You got wood Ade? thats unreal! Who was the cars previous owner? how big was the hole to get that in in the first place!!
removing the sill revealed loads of rotten metal which needed to be removed and new panels welded in place. I spent most of a day patching up inner sill linings and seams to give the new outer panel something to attach to!
http://www.modelnovas.com/images/passill37.JPG
After removing most of the underseal and sound deadening from the sill edges I started work on patching up the passenger seatbelt floor pan area
http://www.modelnovas.com/images/passill39.JPG
This needed 2 sections - one from the floor to the sill and one to the body as well as a new lower section running the length of the rear 1/4 to the arch -
http://www.modelnovas.com/images/passill40.JPG
http://www.modelnovas.com/images/passill41.JPG
new lower section
http://www.modelnovas.com/images/passill42.JPG
http://www.modelnovas.com/images/passill43.JPG
http://www.modelnovas.com/images/passill44.JPG
new rear 1/4 inner section
http://www.modelnovas.com/images/passill45.JPG
These new sections were plug welded to the metal behind them and were ready for the new sill. However I now needed to repair the front mounting section which was more complex because it backed on to the inner front wheel arch. A replacement panel had at some point been welded in there in the past but instead of cutting out the old one they'd just welded fresh metal over rusty - which as we know just rots the fresh metal!
http://www.modelnovas.com/images/passill48.JPG
so I had to cut the "new" metal out to remove what I could of the old and treat what I couldnt get at with krust and sealer
http://www.modelnovas.com/images/passill50.JPG
I then made several replacement panels and rewelded the edges
http://www.modelnovas.com/images/passill51.JPG
Three sections were needed just to strengthen the mounting point
http://www.modelnovas.com/images/passill52.JPG
With most of the inside of the sill repaired (theres a still a small section to do at the front but I need to fit the sill 1st before I can do that) I test fitted the sill again and then cut plug weld holes.
To to this I used a tool called a "joggler" which has a built in hole punch on the back of it. A joggler is like a pair of pliers but it bends metal to form a lip so that when you do a lap weld (which is one bit of metal overlapping another) both panels are nice and flush with one sitting in the groove of the other. The weld then grips both panels making for a very strong weld - the only downside it is leaves a lip on the inside whoch needs properly sealed - however I used weld through primer so a little seam sealer will sort this.
http://www.modelnovas.com/images/passill53.JPG
A pic of the door edge - this is a very fiddley section and needs to line up properly
http://www.modelnovas.com/images/passill54.JPG
everything was gripped tight and I plug welded and ground back the door edge
http://www.modelnovas.com/images/passill62.JPG
front A pillar
http://www.modelnovas.com/images/passill59.JPG
and rear 1/4 panel
http://www.modelnovas.com/images/passill60.JPG
The corner section on the sill was hard to do but came out superbly
http://www.modelnovas.com/images/passill61.JPG
http://www.modelnovas.com/images/passill63.JPG
One new passenger sill
http://www.modelnovas.com/images/passill64.JPG
Theres still the front wheel arch section to finish off and I've also not welded up the lower edge yet - I need to mount the door to ensure the gaps are still level although the replacement sill slotted in to the mounting points smoothly and theres literally no room for moving it!
thats not a bodge, wood is lighter then steel, i can see all the track lads doing it :)
edit, foam is even lighter lol
Quality work Ade :thumb:
ade, check out the rear bumper on this, i know it looks ****e, but with your skill you could make something better
http://www.youtube.com/watch?v=qUn_m...eature=related