Timex and friends

Dollywobbler · Post by **Dollywobbler** » Sat Sep 15, 2012 7:42 pm

Hmmm. We definitely replaced one of the balljoints, or is it the lower ones this time? Nowt to serious though. Phew!

citsncycles · Post by **citsncycles** » Sun Sep 16, 2012 12:40 am

Managed to upload Thursday's pics at last!

Started with an easy one - finishing off the C post!

Then came the tricky bit - the metal surrounding the subframe mount was rotten, but I didn't have time to drop the subframe:

What I've ended up doing is what amounts to a semi temporary repair that should last until I take her off the road for some major work once I have the bodywork completed on the GS (hopefully early spring). First I slipped in an angled repair piece for the inner most face and 'keyhole welded it' from the access hole above and from inside the arch:

I then slid in and welded up a patch on the underside of the 'chassis rail'

Before closing off the inner wing area:

Because of the restricted access, I couldn't remove all the rusty metal, so this comes under the heading 'MOT bodge' I'm afraid, but it should last as long as I need it to, after which it will all be cut out and done again properly.

Next came repairs to the double skinned part of the inner wing, which I cut back to good metal:

A quick roller change on the swager enabled me to easily make up the inner section and weld it in:

The outer section was then repaired after the inner faces of each skin were painted:

Final bit of welding for that day was the passenger side rear footwell, which was previously repaired, but in very poor condition. This is the area with the worst of the rust cut out:

I then simply plated over these holes, as this is another area I plan to revisit, cutting all the old repairs out and replacing it with new metal, shaped like the original section:

The reassembly work in the evening included swapping in the hazard switch from the spare dash, curing the issue with them only working with the ignition on, fitting an interior handle on the rear drivers side door and fiddling with the windscreen washer until it gave at least an approximation of working. No pics of this bit as I was rather preoccupied with getting it ready for the MOT. I also found an issue with the passenger electric window - it's much happier opening than closing! I haven't traced this yet, so have simply disconnected it for now.

Hmmm. We definitely replaced one of the balljoints, or is it the lower ones this time? Nowt to serious though. Phew!

Lowers - although he commented that one looked fairly new ( the advisory side)

citsncycles · Post by **citsncycles** » Mon Sep 17, 2012 12:18 am

Sorted out a load of the MOT issues today, starting with the rear crossmember:

Removal of the rear bumper showed the full extent of the rot - not as bad as it could have been

After cutting all the rot out, I started by repairing the internal dividers:

The rear panel only needed a small repair:

Then I made up and fitted repair pieces for the crossmember. I changed the design slightly, removing the horizontal joint flange that was a rust trap

It was while doing this that I spotted that the back box needed repairs - a couple of quick plates sorted that out:

Making and fitting a new closing panel one side and repairing the panel the other finished this stage of the welding, which was then painted and undersealed:

I then attacked the doors with a hammer and wire brush to get rid of the loose rust, then taped over them as a temporary fix for the MOT:

Doing this I discovered that the stickers on the front doors (ex Tim's DTR) weren't fitted new, as there was filler under the paint on the passenger door.

Next I looked at the headlamp adjustment, but this turned out to be just a detached mounting.

Finally the bolt capping off the fuel leakback pipe was replaced with a piece of bar and a clamp:

All that's left now is the ball joint, which will be done at Tony Weston's tomorrow

Dollywobbler · Post by **Dollywobbler** » Mon Sep 17, 2012 8:50 am

Superb. Gaffer tape worked on the doors last year too! Not a long term solution though as the tape just comes back off... (as you'd probably noticed!). That rear crossmember is so much better than the Green Tiger's - BEFORE you welded it!

citsncycles · Post by **citsncycles** » Tue Sep 18, 2012 12:08 am

Ball joint turned out to be loose in the hub, and screwing it back in sorted it!

The advisory one is clonking though, so I'm ordering a replacement.

Just need to book the retest then sort the tracking

MULLEY · Post by **MULLEY** » Wed Sep 19, 2012 8:12 pm

Wish i could weld

Excellent blog & piccies Mike, you are a true bxer

Caffiend · Post by **Caffiend** » Wed Sep 19, 2012 8:25 pm

I am so looking forward to seeing this car again on Saturday - you have worked wonders already, bet it won't win shed of the show at the next X-rally!

citsncycles · Post by **citsncycles** » Wed Sep 19, 2012 8:29 pm

$\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$

It Passed!

$\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$ $\:D/$

Dollywobbler · Post by **Dollywobbler** » Wed Sep 19, 2012 9:54 pm

Superb. All the best for the trip now! Must be a car transformed.

Philip Chidlow · Post by **Philip Chidlow** » Wed Sep 19, 2012 10:15 pm

EXCELLENT NEWS!!!!

mds141 · Post by **mds141** » Wed Sep 19, 2012 10:28 pm

Well done Mike.

Paul296 · Post by **Paul296** » Wed Sep 19, 2012 11:44 pm

citsncycles · Post by **citsncycles** » Thu Sep 20, 2012 1:13 am

Post by **Tim Leech** » Thu Sep 20, 2012 9:41 am

Excellent news!!!

Mickey taker · Post by **Mickey taker** » Thu Sep 20, 2012 2:03 pm

topman , well done

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