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PostPosted: Tue Aug 15, 2017 4:21 pm 
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Posts: 109
Spent another couple of hours today and feel like I've achieved very little. Just one of those sorts of jobs I suppose. On starting to clean up the edges of where I'd made the first cut I found some more problems. First one being the historic inner sill repair which has rotted out on the weld line.
Image20170815-01 by Angyl Roper, on Flickr

The rear floor pan was actually better than expected so that was something. There's still an awkward bit to chop out all the same. You can also see the messy unfinished end of the repair that I'd already done to the floor this side a while ago, didn't do a better job as I was expecting to have to cut this out a bit more and was limited by the size of the metal I'd got to put in.
Image20170815-02 by Angyl Roper, on Flickr

As I was removing the floor pan up to the seam under the pedals, more metal came off. I reckon I'm going to have to replace this subframe mount completely judging by the state of the metal there.
Image20170815-03 by Angyl Roper, on Flickr

The hole got bigger. The repair is uncomfortably close to the fuel and suspension pipes which I really don't want to have to drop from the car. I'll see what I'm left with when I've done tidying up. I can probably weld the new panel in without moving the pipes if I put a sheet of copper or some kevlar cloth or something between the pipes and the new floor as I work.
Image20170815-04 by Angyl Roper, on Flickr

That was it for today. Don't feel like I've achieved very much really but I know this is the slow part of the job. Putting the panel in is always a lot faster than the prep work.


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PostPosted: Thu Aug 17, 2017 10:29 am 
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Location: High Wycombe, UK
This is a labour of love....few ADO16's are brought back to life from this advanced stage of rust!

The car will love you forever :D :D :D

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1968 MG 1300 Saloon Connaught Green
1972 Triumph 2.5 PI Estate Royal Blue
1978 Carlight Casetta Caravan
http://carlightrestoration.blogspot.co.uk
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PostPosted: Thu Aug 17, 2017 1:00 pm 
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It had better! *shakes fist in its general direction*


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PostPosted: Thu Aug 17, 2017 4:50 pm 
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Got this as high as I could on axle stands since putting it on the ramp didn't go as well as hoped due to the car's age-related metal issues. It started as it always does, with piles of rust. The goal today was to get the front floor pan hole cut out cleanly and the edges prepared for welding in the new pieces.
Image20170817-04 by Angyl Roper, on Flickr

Image20170817-05 by Angyl Roper, on Flickr

There's only a bit of edge cleaning to do now all the rot is chopped out here. There's a lot of metal to put back in again but thankfully most of that is just the floor pan and then a few fiddly edge patches to tie it all together. Not too scary then, right?
Image20170817-06 by Angyl Roper, on Flickr

Not too scary at all until I found some filler and fibreglass and gave it a poke and then found the reason for the sill making horrible noises on this side when trying to lift it with the big lift to make life easier. Turns out the very visible repair inside the car which is nice and solidly attached to the floor and was skimmed with fibreglass resin wasn't so well done on this side. The pigeon poop welds that should attach the floor to the back of the car don't and the whole lot has a skim of fibreglass over rust, which was all cunningly hidden with what looked like thoroughly presentable underseal. Finding this rather took the wind out of my sails.
Image20170817-07 by Angyl Roper, on Flickr

Image20170817-08 by Angyl Roper, on Flickr

I was quite upset when I found that after all the work that's been done so far. Had I known this side of the car was so bad I don't think I would have saved it in all honesty. However, I've put that much work in and this is all within my abilities to put right that I'm going to do just that. I'll finish fitting the floor up front first so there's a good amount more strength in the bottom of the car again and then I'll chop out this bit at the back and rebuild it as properly as I can.

I may take a few days away from this, just to recharge a bit. On the positive side, the other side of the car that's been repaired has been done so far, FAR better and a good jab and bash with tools didn't dislodge anything or find unwanted holes so it's not all bad news.


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PostPosted: Thu Aug 17, 2017 8:34 pm 
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Joined: Thu Aug 08, 2013 3:16 pm
Posts: 5513
yikes!

...'they all do that sir'...

that's going to be a horrid repair, best to drop the rear frame out as the face of the heel board will be mullered as well, its a simple enough repair as its all just flat(ish) plates, but yours is rotten into the box section part which is going to add to the excitement of the job in hand.

my green ones had a good 'patchasauras' in this area, and the orange one has had a much better job done in a much more localised area (you can see the photos of it - and will be able to see the double skinned bits where the frame mounts bolt to)

I think that's its rust in this area and the trumpets that finished most ado16s off in the 70's/80's, could you imagine fixing it with a bolster chisel and gas welding it all back together!

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should you wish, you can contact me on rich@minispares.com

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PostPosted: Thu Aug 17, 2017 9:22 pm 
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I'm thinking chop out the rot and see what's left and then rebuild from there. It's not too bad inside the car and it hasn't crept up the vertical panel very far, it mostly seems to be the floor that's been hit badly and bodged over so I *might* get away without too much frustration here. We shall see.

This definitely tips the car into "should've scrapped it" territory rather than "borderline". Ah well, I'm in too deep to back out now.


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PostPosted: Fri Aug 18, 2017 4:29 pm 
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Just catching up with your work after being away for a little while, your doing a cracking job i wouldn't give up now as your in to deep. That Area is no more difficult to repair than what you've already done.

Its just a rinse and repeat jobbie!

Keep up the good work...it might even post my latest project later on if i remember!


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PostPosted: Fri Aug 18, 2017 4:44 pm 
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Location: Oop North where it's dark & cold nearly all the time.
You are doing a cracking job mate. You always knew that you'd come to the point where you were thinking "Why did I bother", this is it, now put that thought out of your head & crack on!

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PostPosted: Fri Aug 18, 2017 6:46 pm 
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Posts: 109
Thanks for the words of support, it does help :) I have a battle plan for that bit now at least so it's not quite as daunting as it was. I just hope there's no more hidden surprises in here.

From picking the car apart and doing the repairs it looks like the driver's side got some repairs first, most of which were patches over rust. I have no idea how long ago these repairs were done but I'm guessing they were to get it through an MoT probably above a decade ago.. The second round looks like the previous owner's (Rich) work which while ugly is much better quality work with no rust being left in. The work I'm doing is really just a continuation of round 2, finishing off the work Rich had been doing and addressing any new rot problems.

I sat back and looked at the work I've done and I'm absolutely too far in to stop and past the halfway point. It would be silly to back out now after:

- Front inner wing top half replacement
- two front subframe mounts
- repaired front outer wing
- replaced front outer wing
- Front valance repairs
- Inner sill and floor repairs
- Boot floor repairs
- Rear valance repairs

I'm left with
- Floor pan replacement
- Inner sill repairs
- Rear floor pan repair
- Subframe mount repairs
- Outer sill repair
- Subframe mount repair
- Sill closing panel replacement

After that it's all normal on-the-road maintenance levels of repair and I'm not really on a deadline. I've already achieved far more than I ever expected to in a very short period of time and I expect next week I'll have a lot of that massive hole filled back in with steel again which will make the whole thing feel a lot less daunting. Oh, and the Churchill pump has been rebuilt so we need to test that on something and this is an ideal candidate.


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PostPosted: Thu Aug 24, 2017 4:25 pm 
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Had a bit of a setback today. I finally got myself to a point where I had free time and headspace to get on with the floor replacement and filling in that massive hole and in the process of cleaning things back, found that a good deal of the intermediate sill panel is completely gone on the driver's side. Here's what I mean.

Image20170824-01 by Angyl Roper, on Flickr

Image20170824-02 by Angyl Roper, on Flickr

Image20170824-03 by Angyl Roper, on Flickr

The outer sill panel is only attached at the top, there's nothing holding it to the car at the bottom. There's also rot setting in on the outer sill panel. The only remedy here really is full sill replacement and I haven't the money or time for that at the moment. The job I can do is replacing the floor and inner sill portions that need it but before I do that I've still got to address things like the rear subframe mount which isn't actually attached to the car at all because all the bits that hold it on are actually rust and air.
Image20170824-04 by Angyl Roper, on Flickr

This is not what I wanted to discover. Financially, repairing this makes absolutely no sense. Emotionally it doesn't make sense either, I'm not as well invested sentimentally in this car as I am with my others. I know I don't want to scrap it and I know I'll get nothing if I try and sell it so I've decided to mothball the project for the time being. That way I can save up some money, focus on finishing other projects that are eating my spare time and get myself in a healthy position to deal with these problems. It will probably be a few months before I pick this up again and I may dip in and out to do some smaller jobs that don't require more than time investing in them, of which there are quite a few.

For now, the little Austin is sat outside huddled for warmth with the other long-termers and eventually I will get around to getting this sorted, or sold on, or whatever. I'm not going to stress about it. Instead I'll focus on the few bits and bobs the Princess and Rover need that I've been putting off in favour of trying to get the bodywork done on the Austin.
Image20170824-05 by Angyl Roper, on Flickr

Image20170824-06 by Angyl Roper, on Flickr

Mike has been very busy in the background with the Churchill pump and giving it lots of lovely new parts and paint. Just waiting on one fitting arriving in the post before it can be tested.
Image20170824-07 by Angyl Roper, on Flickr

Finally, the spare dashboard (Morris, I think) that came with the Austin is up for grabs should anyone want it. I'm not going to use this so make an offer and it could be yours, sale of that can go into the new sill fund for the 1100.
Image20170824-08 by Angyl Roper, on Flickr


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