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

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Small update.
cut out the other side of the door bottom and clamped the repair patch in place. I used a piece of angle iron as a backing.

Thes is the first section after welding, the old metal was terrible to weld to.

Final position.

And tacked. Put the angle iron on top now to make sure the two patches line up properly. You can see the center piece and the last piece around the corner on top.

 

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Door repairs, next steps.
There was a small piece around the corner that was damaged on the inside from the previous “repairs” that had to be addressed.
Made a small patch that included the extra with around the corner.

All welded.

And brushed.

 

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Dressed the welds a bit.

Next step the middle piece.

And all cleaned up.

 

[mrboatman]

As always amazing work

 

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Finished the bottom.

Fixed some other holes in the front and back of the door.

and fitted the door panel.

Here are both doors with the insides primered.

Ready for assembly.

 

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With the doors mostly done I continue on the body.
First I did the DS inner fender, All fitted and clamped up.

And welded in.

It needs to be finished but it is permanently in there.

 

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Next is the rear, lots of cutting and cleaning.
The corners are made of 4 layers, 3 have to be cut out.

Lots of rust between the layers.

 

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More cutting and cleaning. First corner.

Cleaning up the edge before going for the other corner.

Also cut out the battery box.

 

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A bracket that holds the gas tank had to be moved to the new floor section.
I used the old floor as a template.

Markings on the new floor.

I spot welded the bracket on the new floor piece and started with fitting the new piece.

The fitment is the worst I have seen until now but we will try to make it work.

One side has a large overlap to the wheel well when the other has just a tiny lip.

 

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Besides the bad figment to the old floor there is a bad figment to the rear panel.

Measuring showed that the rear was off by 10 to 15mm.
I used the hydraulic ram to get the rear straight again.

After some gentle massaging of the rear panel the new lower rear panel fitted like it should.

 

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Before the new rear floor can be made to fit I have to fit in the new battery box. I spend a lot of time getting the remains of the old one out. After taking most of the old metal out it was time for some fitting.

It takes some work but the results are rewarding.

 

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Lots of fidling and fitting.

grining And cutting

I still had the crooked rear panel. After pressing it in the correct shape it just came back over night.

On the PS side there was not enough material.

 

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When I got the shape close enough I cleaned up the overlapping areas and coated them with weld primer.

Then I started with one side and worked my way up to the opposite side. Every time I grinder a section to fit with the old material.

This worked well And I got the entire rear tacked in position.
Next I used the hydraulics again the straighten out the rear panel

Once the panels lined up I used the spot welder to make sure it stayed in place this time.

 

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Fully welded the rear floor.

From the inside.

Welded in the missing piece.

And after some grinding.

 

[Kerby J]

That's some great progress that you have made lately!

 

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That's some great progress that you have made lately!

Thanks, almost on the home strech.

 

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The rear valence needed a lot of shaping, it was to narrow and the curve did not follow the rear line.
After some stretching and shrinking the lines match.

Then the corner pieces had to be matched.

Still a way to go.

 

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BEFORE the front can be welded the subframe has to be mounted.
Unfortunately the subframe hs some cracks and a doggy repair.
Here is the poor attempt of fixing the frame.

And here are the other cracks.

After removing the old repair.

I almost forgot to take the picture, started welding already..

 

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After welding and dressing up the welds.

Added some etch primer.

 

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And some chassis paint.

At least this looks better than before.