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**20/07/21 Well, Well, Well ** 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!

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