Build Rebuilding a 40 but no longer in a 1 car garage.

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Welded the brackets back in the beam.

Sprayed weld through primer on the mating surfaces.

 

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Fitted the parts in place.

 

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I wasn’t happy with the fit of the DS frame support. The angle of the floor was off.
So I made a template, cut and bended a piece of steel and schrunk and stretchten it in shape.
Next is cutting and welding.

 

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Fit the inside bottom of the bib in position. Ready for primer and welding.

 

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Corrected the DS bracket and Fitted it.

Connecting to the old steel on both sides.

 

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Made2 discs to position between the frame and the body mount. Plus the DS support bracket taken out of the old support.

S

 

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The B pillar took a big hit when this thing crashed. Tried to pull out the dents but that didn’t work so I took it apart.

Looking to replace the bad parts. Folding some steel.

And some more folding.

And then some

 

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Marking the bad parts.

Cutting the patch and fitting it.

Not sure if this is it, maybe I will make a new patch with a better fit.
Treathed the center boom with Brunox to prevent further rust.

 

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A little lathe work for the bead roller.

Creates the perfect shape for the door opening.

 

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Fitting the patch.

Roughly welded in place, still needs some grinding work.

 

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Its the little stuff that takes most of the time.
Patched the bottom corner andbend the outside of the B pillar untill it fit.

Lots of cleaning done.

Cut and weld on the inner rocker panel. It needs a bit more but its getting there.

 

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Spend some time getting the curve correct

The used the patch to create the curve in the support structure.

 

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Cut,

Fit,

And weld

 

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A few patches later,

And it looks like a solid part again.

 

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Tub support fitting to the inner rocker panel.

 

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And now in position.

 

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Now for the tricky part, making a patch for the corner.
This part needs to connect to the old floor, the new floor, the cross beam and the frame support.
This shows the space that needs to be filled.

The basic shape from the top.

The part that came out.

After some basic shaping.

 

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From a different perspective.
You van see a top piece that will be cut later but this gives me a better reference.

You can already see I made a mistake here. The holes from the welds in the middle of the picture should have been blocked by the support underneath. This showes that the support is not in its correct position.

I tacked the two pieces together only to find out later that it was not correct.

 

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Cut it to the size I expected it to be.

And then started with a new piece of steel.
Here I first schrunk the inside corner an hammered some shape in the metal. After running it through the English wheel a few times you can see a much smoother patch already.

 

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So far for now, after my vacation I will try to fit the pieces together.