where they them bits up the inner arches you could see in the boot? he did well to see them!
You say that but as soon as I was down there they all came out to have a look and had a "poke" (they're all friendly with Rich, and therefore within 5 minutes, me). A crapload of rust came out revealing a hole bigger than my fist The test revealed 2 other similar holes.
That's alright thought because they're now welded up - pictures to come after I'm home from work.
So unfortunately it appears my inebriation for most of the weekend may have hampered my photo taking abilities here. But essentially all repairs needed were undertaken.
Let me be straight up that I'm really not happy with any of these welds. They're strong with plenty of penetration but I really struggled to stop it splattering no matter how much I cleaned up my surfaces. Ah well.
Here we go then. First of all the interior was stripped out and cardboard/plastic boards put up everywhere to protect the car.
So I had some pretty bad rust on the top of both rear arches as well as the side of the other. Bear with the pictures here as some stages are missing:
Other side, with some rust cut out:
Templates were cut:
Metal cut and soaked with the weld-thru:
Other side cut:
What it's like underneath that side:
Makin' the complicated bits:
Like I say, really not proud of these welds but they are at least very solid. I cleaned up all areas again and again so not too sure what was going on. Ah well:
Thems all the pictures for now unfortunately. Update due on Wednesday!
Finally wipers were fitted and the exhaust filled up with weld to stop it blowing. Roll on Wednesday for the retest!
hmm, trying to wrack my brains for when thats happened to me. usually where electrical conductivity is struggling, poor quality metal or some kind of weird coating, power setting too low, or earthing problem (strap had broken from the clamp)
She passed V5 should be with me in a couple of days which means hopefully on the road as daily driver by the end of the month. Before that though I'll need to fix my prop UJ which is knocking and grumbling really badly. I've got a place in mind that should have bearings on the shelf so it shouldn't be an issue to get it done in the next week or so.
Indeed! It was a shower of rust when poked so I think it was being held up there by Japanese will power. The rear door seal/inner arch/rear wing seam is pretty much non existent too. Gonna get around to that once this cold weather buggers off
Those welds really do look horrid.. Looks like a combination of metal that wasn't clean enough (judging by the spatter and the burn marks on the underside) and insufficient welding power, or just wire speed to high. Anyway, great car, glad it passed it's MOT.
Ivan, I think you're bang on. Thinking back to the day now I couldn't even get the sections of plate made from the sheet steel to weld correctly, so I'm very much of the opinion that the metal was contaminated. Despite being in storage, I think it must have rubbed against something really greasy that even powertools wouldn't remove. Welder was absolutely fine and set up correctly.
It's all covered up in seam sealer now so no damage will come of it at least - but I'm going to cut it all out again in the summer and do it properly. There's already a little cringe when I think of the state of it and see those pictures. I set a rule for myself once I got hold of this: This is meant to be a decent car, repaired right. No bodges.
Cheers Mihal, yours looks really tasty in cherry red. Been following your topic closely in the past
I've thrust the Sigma into daily driver duties. This is day 2 and she's doing ok - This week is a test to see if she's capable and to iron out any further issues.
At the moment she has a slight misfire at random intervals so I'm taking it a day at a time to replace ignition parts. So far done plugs, leads, dizzy, rotor. Points looked ok and were gapped to 0.5mm as per the manual.
She starts *perfectly*. First turn of the key, every time. This morning was pretty frosty and the auto choke worked flawlessly.
But every now and again she will be hesitant under acceleration or have a little *blip* now and again. I'm thinking possibly condenser or maybe even coil, not too sure yet. At first I thought it might be a fueling issue, but judging by the temperamental nature of it I'm set on it being something electrical.
Anyway, sat at work now with the financial heads in their posh new cars oggling at the Sigma. Happy man ;D
Post by Mystery Machine on Apr 3, 2013 9:55:45 GMT
I'm so, so glad this is on the road now. I do love this car and really enjoyed watching it in front or behind me all the way back from Dezmondo's gaff.
Sorry I wasn't much help with the car over the play weekend, as you know I was a bit busy with other things but next time I'm hoping to be a bit more helpful? One thing I would seriously recommend for the future: ditch that god awful grinder thing and get a some proper slitting discs, flap wheel and knot wheel etc...
Not only was the noise utterly horrendous (to everyone in the unit) but it seemed to take a lot longer to cut anything that it would have done with a normal grinder/slitting disc. More time to clean the metal up for welding then and less headaches for the rest of us!
Many thanks for the letter in the post the other day, I compeltely forgot to thank you for that.
Boy am I looking forward to seeing this again soon, have I told you how much I love this car?
Nice car mate. Spotted it in the car park at work this morning!
Good to see another Retro rides member working at the 'Share! That makes 3 of us
I know what you mean about the people with the posh cars not really knowing what to make of an old car parked next to them, I am looking forward to tomorrow morning to park my Golf next to the big silver Merc in the next space!!