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**19/09/21 Olive ** Probably how not to restore a Herald!


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40 minutes ago, Colin Lindsay said:

How about making up sections for other people to weld in???  :)

There are so many areas that no-one seems to make panels for, and the suppliers who used to don't answer their e-mails any more...

The suppliers didn't have emails and the mobile phones had very long cords!

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2 hours ago, Mathew said:

The only problem with coming to the end of a project is the compulsion to get another!

This one is a long way from complete, as once the tub is complete it will be time to re-visit the welding on the chassis, before turning my attention to the front bulkhead, which makes the tub look good.

So I reckon there’s at least another 3 months of welding to do, and that is without mention of the bonnet, which I know has a lot of filler in it.

The bonnet however can wait until next winter.

1 hour ago, Colin Lindsay said:

How about making up sections for other people to weld in???  :)

Would you have a customer in mind Colin?

11 hours ago, Pete Lewis said:

you will soon have a new car.

It does rather feel like that.

I think I must have put in about 50 patches and repair panels into the tub alone so far, most of them no bigger than the palm of my hand, and quite a few considerably smaller.

Karl

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  • 4 weeks later...

Is it really a month since I last posted an update?

I haven't been idle, though not necessarily working on the car, as first we had Mrs B birthday, followed by a weekend away in York as a belated birthday treat for Mrs B.

That was 2 out of the last 4 weekends accounted for, with no work done.

So what exactly did I manage to get done in the remaining 2 weekends?

Nothing exciting to be fair, just a lot of welding of panels that I had already fitted last month.

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Having said that, that little lot was about 5 hours worth of welding, grinding and generally cleaning up.

I also took the opportunity to fit the rear over rider support tube, using my trusty piece of dowel and the quarter panel as a jig.

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Which left me with this little bit to fix.

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Not sure why I didn't sort this out earlier, but it is a relatively easy fix, just requiring a small repair patch to be made up.

The patch needs to complete the lip around the boot aperture, so will need to be L-shaped in order to achieve this. 

Now I could try and bend it up out of one piece of steel, but it is far easier to make it out of two sections like these.

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Ignore the rather rough looking strip at the top, it will improve in appearance.

First up tacking the boot lip strip to the rear panel piece.

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Which was then seam welded along the outside edge, and then cleaned up to something a little more acceptable.

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And punched out ready for plug welding in place. The tacks on the inside were further cleaned up after this picture, as the flange needs to be clean to accept the boot seal.

Test fitted.

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And clamped in place ready for welding.

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After which I forgot to take any more pics.

I did also take the opportunity to clean up some scars on the bottom of the rear wings.

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These were simply welded up to restore some strength.

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Then ground back, leaving me with this.

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Much neater.

And finally a new addition to my arsenal...

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I haven't had much of a play with it yet, but it should help with cleaning up some of the more obvious welds, and there are quite a few of them!

Hopefully it won't be a month before the next update.

Karl

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  • Bordfunker changed the title to **30/06/21 Small Steps ** Probably how not to restore a Herald!

Never worry how long your updates are, its progressing and looking good, which is the main point.  I have a few of those air tools of different sizes.  Really good for flatting off although they do use a bit of air. 

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Mat, I know what you mean about them being 'air hungry'. 

I tried this with my usual skinny coil hose and it was very sluggish, but improved massively when I hooked it up directly to the big rubber hose.

The new air tool isn't the only new acquisition on my part, as after much dithering and deliberating I decided to cough up and buy a shrinker/stretcher.

What's one of those I hear you cry? (Alright, maybe not cry exactly)

It's one of these....

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Great, but what does it actually do?

Essentially it does what is says, it shrinks and stretches things, like this....

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Take one piece of flat steel, which was promptly folded up into an L-shape along the black line.

This was then run through the jaws of the shrinker, the shiny chrome bits, which started to impart a curve like this....

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You can see the jaw marks on the steel.

Another couple of runs through gave me this...

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....and with a final run through this.

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I know what you are thinking, all very interesting, but so what?

Remember this?

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I need to sort out the outer edge of the spare wheel well, as currently it is distinctly wonky, so need to create a curved section in the horizontal plane, i.e. across the pic, and an L-shape in the vertical plane to form the back of the well.

As you can see my previous efforts to achieve that were somewhat lacking, and I thought rather than spend £150+ on a new spare wheel well, I'd spend slightly less on a tool that would allow me to fix it, but which will also come in handy for a number of the repairs required on the bulkhead.

That's my rationale and I'm sticking to it, and while I was at it I bought a big sheet of virgin steel to start the new panel with.

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Marked up ready for cutting out.

Time to bend......

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It's amazing how many radii perfectly match an off cut of scaffolding pole!

Here the steel has been persuaded into shape with the aid of a large 'Birmingham screwdriver' over the open jaws of the vice.

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Overall I was quite happy with that, but did need to trim that big flange down as with hindsight, that was never going to work in the shrinker/stretcher.

Long story short, half an hour with the shrinker/stretcher and a selection of hammers and pliers, and I was able to produce this....

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Not perfect, but much better than what was there before.

I used the back of the wheel well to help get the shape right, and this is now trimmed and tacked in, but as usual in my rush to get stuff done, I completely forgot to take any pics.

Overall I'm really impressed by the new tool, even if I do have a lot to learn about how to get the best from it, it has made life a lot easier, and hopefully cheaper in the long run.

Karl

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  • Bordfunker changed the title to **04/07/21 Shrinky/Stretchy ** Probably how not to restore a Herald!

Another progression.  You have a tool that i don't.  Envy at the shrinker/stretcher.  Will be great for lips round wheel arches and other curved areas. I normally make do with a big hammer and anvil/dolly!

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Karl is this a combined shrinker/stretcher, the ones I've seen previously have been separate tools, shrinker grabs the steel and pulls it in the stretcher the opposite grabs and pulls it out. Two biggish & heavy tools to find a home for.

Does yours have a neutral point and you can push or pull the lever creating the shrink or stretch action, if so great one tool does both great solution.

great job by the way and an impressive bit of gear so many uses. 

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Mat, I have been eyeing one of these up for almost year now, and really ought to have bought it when I was doing the passenger side rear wheel arch.

Pete, mine came with two sets of jaws, one for stretching, the other for shrinking, you just swap them around depending on what you need to do.

It’s not very big either, and the handle comes off, so it can be tucked away without taking up too much space.

Karl

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Pete, I got mine from Frost in the UK.

No makers marks on the box or the tool itself unfortunately, but there appear to be plenty similar out on the web for less than I paid.

I have used Frost in the past so was happy to pay a bit more for peace of mind.

Karl

 

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  • 2 weeks later...

After a week off from the garage last week, due to a bad back, my own fault, and ironically caused by overdoing exercises to address a stiff buttock (Don't laugh), I decided to head back into the gloom on the hottest weekend of the year!

I never claimed to be bright.

Now, last time I had made up a repair panel for the front face of the spare wheel well, but coming back to it after a couple of weeks, I just wasn't happy with it, and so decided to cut it out and start again.

This time I split it into two sections, the outer vertical wall of the well, and then the curved portion that transitions to the flat base of the well.

The first bit was easy...

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....even I couldn't cock up forming that section.

Which then got welded in. 

First tacked....

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...then seam welded.

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Not my neatest bit of welding, but not helped by continually bashing my head against the spare wheel bracket (At least I was wearing a welding helmet), and the fact I kept steaming up my welding helmet in the heat!

The bulk of that was done Saturday afternoon, which left Sunday afternoon to tackle the difficult bit, namely the curved section, which curves across two planes.

As before, I initially created the curve of the transition from the floor of the wheel well to the vertical wall with a section of scaffolding pole, leaving me with a long semi-U shaped piece of steel.

This is where the shrinker/stretcher came into it's own allowing me to impart the curve across the piece of steel to create the second section of the repair panel.

This meant several hours of tweaking, shrinking, then a bit of stretching, then a bit more shrinking, then a bit more tweaking to try and obtain the best fit possible.

It is at this point that I understand why car bodywork repairs can be so expensive, given how time consuming it is, though I appreciate that I am a complete amateur, and therefore much, much,  slower than a professional would be.

Here it is tacked in...

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...note a couple of very dodgy looking tacks because someone had forgotten to turn the shielding gas on! No matter as they will be ground back, and then seam welded.

Here's the view from the top.

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As you can see I have cut out the previous repair section at the front of the well, and have a bit more tidying up to do before I do the final tacks and welding in of this portion.

It's a bit annoying going back and starting again, but I am much happier with this attempt than the last, and it's a good opportunity to try and develop some metalworking skills.

Karl

 

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  • Bordfunker changed the title to **20/07/21 Well, Well, Well ** Probably how not to restore a Herald!
  • 4 weeks later...

I seem to making a habit of these long pauses between updates, but in my defense it has been very busy in the Bordfunker house of late.

Firstly my eldest son and his girlfriend moved to a flat in North London, which meant a long promised trip to Bovington Tank Museum to go seem some real heavy metal, including the amusingly named Standard Beaverette!

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The following weekend was then spent moving them both from Banbury to Wood Green, a journey that takes a lot longer than you would think! 

Not helped by insane scooter riders who seem hell bent of throwing themselves in front of you at ever set of lights!

Which brings us up to last weekend, which, obviously, given that we now had a 'spare bedroom', meant setting it up to act as my wife's new craft room, followed by moving a load of stuff from the living room into the new craft room rendering it unusable as a craft room!

The reason for this insanity was that I took last week off in order to decorate the dining/living room, something that we had been planning to do for at least the last 5 years.

Let's be clear, I hate decorating, but there is no way I am going to pay someone else do something that I know full well, that I should be able to do.

Cue 4 days of decorating this week, before Mrs B headed off to Sheffield to see friends, leaving me at a loose end for 3 days. What do?

Garage obviously!

But first a trip to the tip, as the garage has become a bit of a dumping ground, making it not only difficult, but also dangerous, to work in.

So now we've got the shaggy dog story out of the way, along with the rubbish, it was time to make up the last patch for the spare wheel well.

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To fill the yawning chasm here.

To make matters more awkward, the section also includes three reinforcing ribs, for which I used my wonderfully clever block of wood with a rib shape carved out of it.

Clamp steel over block, making sure you have the rib where you need it, then then apply force!

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I wasn't aiming for perfect, but I did do a bit more finessing before I finally fitted the panel, as I'm going to stone chip the front of the wheel well as it does appear to come in for quite a lot of punishment based on mine.

What followed was an hour of fettling, checking, fettling, checking and then finally deciding that everything fitted about as well as it was going to.

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I was quite impressed by the fit I managed to achieve, which mean it was welding time!

Tacks first...

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...followed by a laboriously seam welding it all, a little bit at a time to avoid heat distortion.

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Overall pretty good, and only 3 pin holes. 

As you can see I have also made a start on re-welding the old repair section that I put in a couple of years back when the welder wasn't playing ball.

And here it is all welded up.

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Again, I'm not aiming for perfect here, just a properly welded repair, particularly as this will be seam sealed and then stone chipped.

That and it's underneath the car, so only me and the MoT man will ever really see it!

And with that in mind, I revisited the patches that I had welded in for the outer seat belt mounts, going belt and braces to be ultra cautious.

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Hopefully that will keep the MoT man happy, and the seatbelts properly anchored.

All of the above meant that I was finally approaching the end of the welding marathon that has been the rear tub, with just one little patch left to do, when this happened...

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Oops, out of gas!

But it was 4.30 on a Saturday afternoon, no problem?

Problem! My local stockist was out of Hobbyweld 5, and I didn't fancy chasing around Oxfordshire and Northamptonshire looking for some, so called it a day on the welding for this weekend.

But with Mrs B not back until Monday, what to do with Sunday, other than mow the lawn, and fit the curtain rail brackets in the living room?

Nothing for it but to continue cleaning the crud and underseal from the front of the tub, which I started last year before commencing the welding marathon.

Four hours of scraping, wire brushing and wiping down with white spirit, left me with this.

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And this is what the other side looks like, and what the above side had started the afternoon looking like.

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I know what next weekend has in store for me, along with a bit more decorating.

It would have been lovely to have finally got the welding on the tub completed this weekend, but the welding gas gods were not smiling on me this time, so it will have to wait for another week.

Karl

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  • Bordfunker changed the title to **15/08/21 Almost there ** Probably how not to restore a Herald!

I have been watching the updates for long while as you know Karl, and you have the theory "practice makes perfect" is true. Your welding and fabrication skills are great and much faster... Well done that man :) 

Tony. 

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  • 2 weeks later...

Thanks for the words of encouragement Tony, much appreciated.

After last week's lack of welding gas driven hiatus, I was rather hoping to get the last of the welding done this week, but a call to the farm shop confirmed that they had still not had a delivery of gas, so rather than go chasing around Oxfordshire looking for gas, I decided to focus on some more of the dull stuff.

Now I had thought that I had removed all of the dreaded under seal from the underside of the tub, but alas no, I hadn't, and in places there was a very thin layer of the stuff still adhering to the surface.

I tried white spirit and brush cleaner, but that just seemed to move it around, rather than actually removing it.

So I got a little brutal and hit it with the heat gun on max, so that the oily element of the underseal burnt off, good ventilation is a must for this, then scraping off the carbonised remains.

The tub then got a good coat of FE 123 rust stopper, which was then left to harden off overnight.

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Which is where I intending to leave it for this week, but then yesterday afternoon turned out sunny and mild, and work had wrapped up promptly at 5, leaving me some time on my hands.

What to do?

Given that I have had a couple of tins of red oxide epoxy mastic sitting under my desk in the study since the spring, it seemed the time was ripe to slap some paint on.

The point of this exercise was not so much to provide a perfect coat of paint, but to cover up and protect the areas that I had already prepped in order to avoid flash rusting undoing all my hard work.

So with that in mind, rather than break out the spray gun and fire up the compressor, I decided to go old skool and use a hairy stick.

It's not quite Matt's standard on his Puma Spit, but it will do.

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I would have painted more, but my workshop vacuum died last weekend, and I needed to clean up areas like the wheel arches before I could apply paint.

Guess who's Googling 'How to fault find a vacuum cleaner?' this week?

The aim is to get the underside of the tub fully welded, then painted with epoxy primer, then flip it over and make sure that everything fits as it should to the chassis and bulkhead.

I can then make any amendments to ensure everything fits properly, then the tub will be flipped again, with the chassis and tub underside getting a thorough rub down, followed by spray coats of epoxy mastic, followed by seam sealing.

That little lot should take me well into autumn, assuming no major upsets, and then it will be time to return to the bulkhead.

I'm less nervous of the bulkhead now that the welder is working as it should, and I know that I can both reliably stick two pieces of metal together, and generally shape them into an approximation of the required shape.

Karl

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  • Bordfunker changed the title to **24/08/21 Paint Your Wagon ** Probably how not to restore a Herald!
  • 4 weeks later...

We have a new addition to the Bordfunker household....

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This is Olive, an 8 week old Beagle pup who we picked up last weekend from the breeder in Lincolnshire.

Which has meant the last few weekends have been spent puppy proofing the house and the garden, as we have never had a puppy since moving in here, and there were a number of small gaps in fences and under gates that needed addressing.

And given that she is a pup, most of this week has passed in a sleep deprived haze, but I'm hoping that will improve. 

It's amazing, you forget all this once they are beyond puppyhood, just like you do with kids!

So this is essentially a long excuse for a) not posting recently, and b) not getting a lot done on the Herald.

This update is therefore a couple of weeks old, as we last saw the underside of the Herald's tub part painted and de-rusted, and with the focus on cleaning up the remaining sections ahead of the cold damp weather of winter.

Cue new purchase..

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It's a Norton strip disc, not cheap, at almost £12 from Screwfix, but wow! does it take the crud off!

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Which is good, because by the time I had done this lot it was as bald as a Coot!

Speaking of bald, this is the state of my cup brush after attacking all the areas the strip disc couldn't reach.

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I ended up with one of the wires stuck in my chin, and a rash on my right arm where they had been flying off!

I also managed to finish off that last bit of welding around passenger side boot drain hole.

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Not sure whether to drill this out or leave as is at the moment.

Everything has now been stripped back, except the spare wheel well which was already painted, and so will just get flatted back, and a coat of rust stopper applied for immediate protection.

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The above pic looks like a before and after view, with a bit of in between for good measure, however all of the cruddy bits have now been cleaned up and rust stopper applied.

Now I just need to find an hour or so to mix up the epoxy mastic, and give everything a protective coat ahead of the weather turning.

Not sure when the next update will be, but I do remember that puppies do grow very quickly, so hopefully not to long.

Karl

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  • Bordfunker changed the title to **19/09/21 Olive ** Probably how not to restore a Herald!

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