Nice job Steve, although I don't know that Workcover would be happy with the state of that workplace.

Regards,
Craig.

Is that A pillar an off the shelf repair panel or did you knock it up yourself? I will need to find one for the right and left hand side.
how is the fit?

quote:

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Originally posted by Escortpower

Nice job Steve, although I don't know that Workcover would be happy with the state of that workplace.

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I'm not particulary happy with it either but I needed to make hay last week as next week will be a little slower. Tomorrow morning is clean up day. Next weeks shifts are more civilised hours but it means less time on the car than when I do lates.

quote:

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Originally posted by Jason How

Is that A pillar an off the shelf repair panel or did you knock it up yourself? I will need to find one for the right and left hand side.
how is the fit?

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The A pillar is an off the shelf repair panel from Expressed Panels in the UK. The fit is excellent. There are actually three parts to the A pillar so make sure of which ones you need to fix. Mine had only gone on the external side. The internal is fine and the strengthener is solid.

Cleaned up a bit today. Also did some painting in preparation for welding the A pillar back together.

Cracking progress Steve

Decided on the suspension dampers today. Also figured out the front braking. Now to start saving up.

Nice progress steve.

Are you drilling and then plug welding the panel in place? If so are you removing the paint on the mating flanges? I used a weld through primer to ensure I gave it the best possible protection once welded.

Yup. Drilling and plug welding combined with butt welding. There will be a few spots that have the paint removed but not many. I'll see how it goes. Shouldn't be too many issues with water getting back into the A pillar. Most of the trouble was caused by a dodgy repair done before i got the car.

Welded the A pillar back on today... and ran out of MIG gas. Just have to grind a few welds flat (the visible ones).

First step was to weld the bottom part to the sill then the top to the original pillar. This was so both matched fairly closely as they'll be the visible part of the repair.

Next was the inner A pillar to the replacement along the door opening from top to bottom.

Then i drilled some new holes in the replacement A pillar along the front join and plug welded the new pillar to the inner pillar. Then i folded the forward outer panel back and plug welded through the holes left by the spot weld drill.

At this point I ran out of gas.

There's one patch left to do then the whole area gets a coat of etch primer then the seam sealer.









Also put in an order for a few more chassis gussets and strengthening bits. Should be here in a couple of weeks.

Next big job is the C pillar vents.

Very nice Steve, no mucking around there. Must have been a fun job to unpick all the welds in the pilar. Pity about the gas running out. It always seems to be the little things that spoil the jobs finish time. Anyone open for the sale of MIG gas near you this week? Keep up the good work.

Regards,
Craig.