The part i need to weld is the other side of the overlap. I'm not welding into the back of the welds i've just done.

Nice dolly Fordsy. What dimension is the metal? I was thinking of using 50x50x2. Mine will need to cope with several trips on the back of a trailer. I am also probably going to use the jacking holes int he chassis to secure the shell to the dolly.

WHat height do your chassis rails sit at??

I'm fairly sure it's 50x50x2. The dolly is 1m wide and 1.5m long. The uprights are 33cm. The front top crossbar is 1m wide. The back is 1.3m wide on account of the change in rail spacing. The height from the floor to the chassis rails is about 55cm which is very handy for working around the car. It means i can sit on a chair while welding on most parts of the outside.

I'll measure the exact height to the chassis rails tomorrow when i get a chance.

The frame is 50x50x2. Chassis height is 55cm above the floor.

Here's todays progress.

I've finished the welding on the firewall. The top lip has been folded down and welded.




Having done that, i installed the front chassis gussets.

Looks great Steve

There's nothing like a big project to get the juices flowing[:p]

quote:

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Originally posted by Phil

Looks great Steve

There's nothing like a big project to get the juices flowing[:p]

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I could not agree any more.
We have been a little thin with new projects.

Thanks for showing what the gusset looks like in it's raw state.
Many are too afraid to share.
Keep up the great work Steve.

Looking at the pic's of the gussets, just wondering if they'll trap water and dirt in 'em being that there's a small opening at the top (just where water would flow down) and are fully welded at bottom? Might be a rust problem in the making

Not knocking you're work Steve, as you've done a heck of a good job. It's the first time I've actually seen pic's of the gussets before painting. I'm thinking maybe cut out a little bit off the bottom edge of the gusset where it meets the firewall and rail to let any water and dirt that get's trap out before welding?? What do you guys think?

Agree....do anything to keep the worms at bay!!!!!

Yeah. I'm aware of that opening. There's also an opening in the firewall behind the gusset the normally has an oval shaped plug.

I left the hole there so i could make sure that i could access behind the gusset in the restoration stage so i can fill it with fish oil or the like then seal it up. The other option is to fill it with structural foam.

I'll get a photo from inside the car tomorrow to show the access holes in the firewall.

Today's work.

The slam panel and front panel have been removed. I was going to take the drivers side wing off to allow me to weld the inner wing but there should be enough space for me to leave it on. This should help align the front when i get around to replacing it.





The firewall, engine bay and gusseting with all get a good coat of POR15. That should prevent the rust returning.