Jump to content

Recommended Posts

Hope everyone is having a good Labor Day weekend so far, meaning they are Laboriously working on their cars!

 

I hit the garage again today, as I want to get the trunk area complete sometime soon.  It's a mess and want to get past it and get the body finished, which will put me in the home stretch with the MGA.  

 

I made a cardboard template of the primary hole in the trunk, then traced it onto some sheet steel, allowing for an extra 1" on the far end to go under the cross member.  This section also has a small folded-down area at the front end (of the entire trunk panel) for strength.  The vertical piece where the spare tire goes thru is then spot-welded to the trunk floor.  It was badly rusted, so I cut most of this area out (it is towards the front of the car, obscured by the vertical spare-tire hole piece), but I left most of the lower spare time hole piece as it is pretty good and needed for some structural integrity, plus all the holes are still there, where rivets will eventually go to secure the spare tire cover assembly.  I was able to bend down the front end of the new steel piece by just placing over the edge of my workbench, clamping it, and hammering it with body hammers.  I have some excess, so I'll eventually cut that off to match with the remaining sections on either side that I didn't cut out.

 

Here's the patch panel, loosely clamped in (Photo 1).  Here it is tacked in (Photo 2).  The tacking went much better than I thought, considering the thin and pitted remains I'm trying to work with.  I'm sure that when I start to fill it in more, I'll get the same typical blow thrus, pinholes, and other problems I always have, but off to a good start.   Here's a last photo with the cardboard I cut out and the steel I cut out.  Worked really well, for just having simple hand tools and an angle grinder.  I'll try to tackle a little more tomorrow, and maybe finish the welding, or tack in another few patches.

 

Cheers,

Chris

100_6915.JPG

100_6916.JPG

100_6917.JPG

  • Like 3
Link to post
Share on other sites

Some baby steps today, too much other stuff going on.  First, I plugged another rust hole in the trunk using the copper backing method (Photo 1).  Turned out well.

 

I then continued to fill in the seam on the large patch I installed.  As I expected, I ended up chasing burn thru hole that were mostly mad in the thin original metal, but I thought it went better than I thought it would.  Here's as far as I got, maybe about 80% finished (Photo 2).  Here's a view from inside the body looking back towards the trunk.  You can see the bent down section I had to make in the new steel, which I will later trim to match the correct height.  You can see a small piece of the original section to the far left.  This view shows a lot of the pin holes and all the giant mounds of weld I built from trying to chase burn holes and pin holes (Photo 3).  Once I ground it down, it looked much better, I think Photo 2 is after grinded it all down.  Unfortunately, I've been so busy, I can only get in about 2 solid hours each day on the weekend, which isn't much.  I'll have to take some dedicated MGA days off sometime soon so I can get more accomplished.

 

Next round, I'll continue chasing pinholes and probably tack in the next largest patch, and maybe fill a few more small holes.

100_6920.JPG

100_6924.JPG

100_6923.JPG

Edited by hursst (see edit history)
  • Like 2
Link to post
Share on other sites

Good advice, but I need to try to keep as much metal as I can to avoid the curves and patterned areas, as that will be much more difficult to try to reproduce.  I may have no choice but to make more cuts, but so far so good.  I'll probably have to cut out more areas that have a lot of small holes, you can see them in the photo, but I'm going to wait until I get some of the bigger patches done to give it some more integrity first.  Thanks again!

  • Like 1
Link to post
Share on other sites
15 hours ago, hursst said:

Good advice, but I need to try to keep as much metal as I can to avoid the curves and patterned areas, as that will be much more difficult to try to reproduce.  I may have no choice but to make more cuts, but so far so good.  I'll probably have to cut out more areas that have a lot of small holes, you can see them in the photo, but I'm going to wait until I get some of the bigger patches done to give it some more integrity first.  Thanks again!

 

I think you'll find that making the shapes in the areas you need to cut out is not as difficult as you'd imagine.  You don't need bead rollers and English wheels and all that fancy stuff.   I'm sure if you look around your shop there are all kinds of shapes that, in some small part, look like some small part of the patterns in the trunk.  I think the trick is to get a thin sheet of aluminum and, with wild abandon, start beating it into the shape you need.  You might do that a couple of times and then you'll figure out a technique that works... grab the correct steel sheet and repeat.   I'm not there and can't see the whole trunk so my advice might be pretty bad... but hey.. it was free!!

 

I'm not completely sure that was clear.  You can cut patterns out of hard wood or, if you have it, thick steel and use those to hammer the sheet steel against.  You can get the sheet nice and hot and it become very easy to form.  In addition to an anvil, things like railroad rail, bowling balls, vintage shoe makers forms, etc can provide a bunch of shapes to help you form what you need.  It takes a good bit of trial and error which takes time, but so does welding rusty metal.

 

Edited by Luv2Wrench (see edit history)
Link to post
Share on other sites

Jeff, makes sense, all good advice.  I've been doing that already, to a small extent, but I'll have to give it more thought if I get into trouble.  I have cut away a lot already, and have identified some more areas I'll have to cut, but I'll have to weigh being able to salvage some areas vs. The extra work of having to make more complex shapes.  As usual, thanks for the welcome advice.

  • Like 1
Link to post
Share on other sites

Adding to Jeff's advice. I found a leather covered sandbag was my most useful 'tool' for making shapes. I bought mine second hand and have had it for years.

f228_1-300x203.jpg.2d64370f4a180dae0ded528720b026d1.jpg

It's a shame we are on different sides of the 'large pond' as I am unable too use my panel beating equipment anymore and I suppose it will have to find a new home. I maybe able to empty the sand out of it and then it would be much cheaper to post? Mike

  • Like 2
Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
×
×
  • Create New...