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Learning how to build Lotus Seven replicas...together!
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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 15, 2014, 10:07 pm 
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andrewt wrote:
Looks good. I'm following this one closely. I always thought with my new found rudimentary metalworking skills I've acquired building the Locost, I would tackle replacing floors and other simple flat surfaces on a rusty vintage car. Minis are on the long list of potential cars I always have an eye out for locally. Keep updating the facebook page. I may not comment much, but I'm enjoying the updates when I can't get on locostusa.com.


I'll keep posting regular updates on the fb page as well as here.

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OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 16, 2014, 4:45 pm 
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Bob, there are no reasonable carriers and there's customs as well.

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 16, 2014, 6:45 pm 
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Have you guys over there tried a joggle /punch tool and plug welding on your tin worm projects? Its much easier, neater, more than strong enough, causes no distortion and looks like the factory spot welds.

Bob

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 19, 2014, 1:03 pm 
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Bob
Some areas will get plug welds. The top run of the inner sills in particular. Any work I do on the outer body and seam panels, and replacing the companion box in the rear.

I seriously thought about just plug welding the floor patches, but the more rot I cut out of the floors from prior patch work, the more I wanted fully welded seams.
My normal plan would be fully welded butt joints. The panels on the Mini seem to be several different gauges. The floors look and feel like 18 ga. The toe board reinforcements are thicker, about 16 ga, and the inner fenders are thinner, feels about 20 ga. I struggled with getting a setting that didn't blow through the old steel, so I went to overlap. I know I can keep most of the heat on the new steel, then flow the puddle toward the old stuff.

Lots and lots of small tacks help keep if from flaring apart as I work.

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Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 19, 2014, 4:46 pm 
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Bob, correct me if i wrong but any repairs in a floor or a structural member if not at the original weld seam must be fully welded and no braize used if you want it to pass an MOT test in the U.K.?

its been a long time since i did MOT work.

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 20, 2014, 8:11 am 
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Ugly day in SC. Lots of rain in the forecast, but it doesn't rain in the garage. :D
Finishing my coffee and headed out there in a few minutes... stay tuned for updates later today.

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OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 20, 2014, 7:50 pm 
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Long day in the garage today. I took a reasonable number of pics, so this will probably be two posts.
Started with the left front pan. I had cut a hole in it last weekend. I got out there this morning with a pick hammer and a punch to see of there were more thin spots, or if I could just put in a patch.
Attachment:
lf1.JPG
lf1.JPG [ 673.56 KiB | Viewed 2238 times ]


Turns out it's solid, so I can just put in a patch.
Held the floor pan up to the hole to mark.
Attachment:
lf2.JPG
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A little trimming.
Attachment:
lf3.JPG
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A little shaping. Had to bend the shape of the inner sill, then had to reshape the beaded area to turn it into a well instead of a bead.
Last order of business was a little hammering to get it to fit tight to the transition to the toe board.
Attachment:
lf4.JPG
lf4.JPG [ 631.81 KiB | Viewed 2238 times ]


Tacked in and started stitch welding.
Attachment:
lf5.JPG
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A little more stich welding...
Attachment:
lf6.JPG
lf6.JPG [ 648.59 KiB | Viewed 2238 times ]


and finally welded in. Waaaaay easier than the other side.
Attachment:
lf7.JPG
lf7.JPG [ 784.82 KiB | Viewed 2238 times ]


Time to start a new post to show the left rear work as it progressed.

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Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 20, 2014, 8:08 pm 
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Now for the left rear. This is where the cancer was serious and I was scared. I can't take out all the rusty parts at once or I'll have to weld in a bunch of braces to keep the shell from moving about.

Time to cut out a floor. A narrow cutting blade on the angle grinder went through the rough cutting really quick.
Attachment:
lr1.JPG
lr1.JPG [ 580.08 KiB | Viewed 2235 times ]


The end of the heel board is rotten. This is what the rear subframe bolts to, the inner and outer sills weld to, and the shut panel and rear seat bottom rest on.
It needs to have the right dimensions or I'll suffer down the road when stuff starts going back together.
Lets get some working dimensions.
Attachment:
lr2.JPG
lr2.JPG [ 293.62 KiB | Viewed 2235 times ]

Attachment:
lr3.JPG
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Attachment:
lr4.JPG
lr4.JPG [ 343.63 KiB | Viewed 2235 times ]


OK, lets cut out the rotten part. Man that's ugly
Attachment:
lr5.JPG
lr5.JPG [ 415.98 KiB | Viewed 2235 times ]


Now time to make a replacement. Transfer some dimensions, mark it out, look at it, mark some more, look at it some more.
Attachment:
lr6.JPG
lr6.JPG [ 842.76 KiB | Viewed 2235 times ]


start cutting and forming
Attachment:
lr7.JPG
lr7.JPG [ 1012.52 KiB | Viewed 2235 times ]

Attachment:
lr8.JPG
lr8.JPG [ 886.62 KiB | Viewed 2235 times ]


Then weld it in. I used a straightedge to be sure I had it running in line with the rest of the heel board.
Attachment:
lr9.JPG
lr9.JPG [ 479.02 KiB | Viewed 2235 times ]


I won't bore you guys with the pics, but the outer rocker on that side looked like swiss cheese when I ground off the paint. I cut away part of it, then vacuumed out about 10 lbs of dirt, I think about an acre of NZ was in there.

time for another post, tired of scrolling to put pics in line.

_________________
Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 20, 2014, 8:18 pm 
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Where was I? Oh yeah, rear floor pan.
With the heel board repaired I could get to work on the floor pan.

Test fit and put on some reference marks so I can line it up the same without using clecos.
Attachment:
lr10.JPG
lr10.JPG [ 617.98 KiB | Viewed 2234 times ]

Attachment:
lr11.JPG
lr11.JPG [ 645.23 KiB | Viewed 2234 times ]


I marked a line to bend t he pan, so it would have the same upward flare as stock, then did a little cutting and bending to make a doubler for the inner sill. Sorry, those pics were completely fuzzy, so I deleted them.

A couple more test fits, then tack it in place.
Attachment:
lr12.JPG
lr12.JPG [ 560.79 KiB | Viewed 2234 times ]


Fully tacked, stitching started.
Attachment:
lr13.JPG
lr13.JPG [ 658.65 KiB | Viewed 2234 times ]


Realized I was hungry, looked at the time and it was 6:15... time to call it a day and watch some Tiger football.

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Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 21, 2014, 11:23 am 
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time to call it a day and watch some Tiger football.

Heckuva game, too... Some "homefield advantage" calls for FSU... Tough one for Clemson.

My alma mater, NC State, played some private girl's school and won... Yawn... I didn't watch it.

Now would ya get back in the garage!!! :mrgreen:

JDK

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"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 21, 2014, 7:11 pm 
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Just for you JD, back in the garage today. Wasn't much in the mood for fully welding the LR pan, so started work on RR. O was hoping it was better than the LR... it wasn't :(

Whole pan cut out, left the companion box this time. Don't know if it saved time, but it sure made working on the inner sill a pain in the azz
Attachment:
rr1.JPG
rr1.JPG [ 674.41 KiB | Viewed 2183 times ]


Heel board looks pretty good, bottom of the inner sill is punky. Time to cut some more
Attachment:
rr2.JPG
rr2.JPG [ 635.01 KiB | Viewed 2183 times ]


Did I mention someone had welded on an oversill on the Right side? It was covering up a world of rust on the outer sill and jacking point. Cut off the oversill, outer sill, jacking point, and a small piece of the inner sill
Attachment:
rr3.JPG
rr3.JPG [ 546.6 KiB | Viewed 2183 times ]


Patched inner sill at the heel board and that section in the previous pic.
Attachment:
rr4.JPG
rr4.JPG [ 458.27 KiB | Viewed 2183 times ]


Then it was time to start fitting the floor pan... finally. Decided that clecos were much easier for getting it back in the same place multiple times. This went pretty much like the other side; bend it same shape as the original, trim to fit.
Attachment:
rr5.JPG
rr5.JPG [ 451.02 KiB | Viewed 2183 times ]


Then once it fits like it should, tack and stitch.
Attachment:
rr6.JPG
rr6.JPG [ 594.08 KiB | Viewed 2183 times ]


I accidentally touched the torch to my forearm rolling out from under the car.
Attachment:
ouch.JPG
ouch.JPG [ 672.72 KiB | Viewed 2183 times ]



Oh, and wile I was working on the car I was working on dinner. Spare ribs on the smoker
Attachment:
a1.JPG
a1.JPG [ 574.51 KiB | Viewed 2183 times ]


fast forward 2 hours... wrap them up in foil at this point and give them 2 more hours at 250 degrees.
Attachment:
a2.JPG
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Dinner. Spare ribs, fried okra, broccoli and cheese, kimchee
Attachment:
a3.JPG
a3.JPG [ 728.58 KiB | Viewed 2183 times ]

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Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 21, 2014, 7:50 pm 
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Well you had me till the Kimchee.

I'm not one for sour foods.

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 21, 2014, 7:56 pm 
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I usually do slaw, was lazy after being in the heat today.

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Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: September 21, 2014, 8:41 pm 
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Thanks for the update... Bet that arm hurts like a bitc.... Well, you know...

Ribs look good. Just smoke flavored, or did you baste 'em with something or marinate or whatever?

For the record, I LOVE kimchee!!!

Looks like a very good day, Bro!
:cheers:
JDK

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Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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PostPosted: September 21, 2014, 8:53 pm 
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Just smoke on the ribs, apple and oak. Turkey or chicken I brine overnight. A whole shoulder gets dry rub.

Beer thirty now
:cheers:

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Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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