Page 5

The bottom of the front panel continued.

Following on from the last page the repair panel has been cut in three pieces and then cut in half again horizontally, you can see in the picture that I have already welded the center section in place. In doing it this way you can leave the outer remaining parts in place to make sure that the center section lines up correctly. The new panel was holed along the top edge on the inside and outside, and the panel to which it was joined was lapped. It also joins the front at the cassis rails so a good weld can be laid down at the ends of the panel to the underside of the cassis rail.

Here you can see the welds on the underside, and maybe I should say I hate welding underneath vehicles! (with a passion), just incase the welds look a bit dodgy. I cleaned all the areas to be welded back to nice clean metal so the welding wasn't to hard. (I use a mig welder)

In the large picture you can see where the join to the cassis rail is (in this picture all the front panel has been replaced). From underneath you can see that there is a bit of surface rust on some of the surrounding panels but in general the underneath is very good.

Now onto the corner, you can see that the outer panel of the lower panel has been removed and the area is quite bad. There is a hole at the bottom of the a post which will need attention but the right edge is in good condition. At this point it is ok to cut out the rest of the old panel as you have three reference points to work with so shouldn't lose the shape of the panel. The three references are the center section, the bottom of the chassis rail and the a post. But before I cut it out I had to get a template of the panel which closes up the end of the front panel at the bottom. You can see where this panel joins the front panel by the gap. (you might have to look at the big picture) This part doesn't come as part of the repair panel.

Here is the repair panel I have made, just to make sure it fits I have tried it out with the rest of the front panel still in place all thought I didn't weld it in place at this stage. I couldn't find a repair panel for this area which is a shame as if you are replacing the front panel then you will probably have to repair this area.

Here is the repaired area, I have cut out all the old metal, which also included the flange which the home made panel (in above picture) fits to.

You can also see the bottom of the chassis rail which the front panel will rest on. Also if you are sharp you might have noticed that the steering box is still in place. The steering box had to be moved out of the way, but this turned out to be easier said then done. To remove the steering box you must get the drop arm of the shaft and this isn't easy as it had been on there for 28 years and basically didn't want to come of. To cut a long story short (two weeks but I wont go into that) I had to hire a hydraulic bearing puller to get it of.

That looks better, the new panel welded in place. This picture show the method I use for welding in the panels. Weld through the holes to the lapped back panel then once in place weld all along the joint, this should be well strong enough, and if water should leak in it cant sit in the lap as the un-welded part is on the inside at the bottom so any water should just drip over the lap. I am however going to inject loads of wax oil into all of the cavities to make sure I don't have any problems.

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Please feel free to e-mail me with suggestions or questions and I will try and oblige.

E-Mail me : fid@fid-tech-ltd.com

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