Roverjoe Posted September 14, 2023 Author Share Posted September 14, 2023 So Today i have sorted out the boot floor finally, as it was starting to get on my nerves a bit. but its all welded, seam sealed and painted. alongside the refitting of the tow eye reinforcer. i also jacked it up to see if it would break, it didnt! which is great. Later on i started to work on the passenger side sill, i have cut away an area to gain access to the lower section, this will then be cut further out when i fit the new upper piece in. I will be fabricating new reinforcer panels, perhaps a new jacking point panel and the panel that joins the sill to the arch. Ive cut the area out of the arch out as i have a New old Stock panel to go in place, i also have a fabricated lower sill that i made earlier on in the year which will be getting cut to size to be butt welded in. I have also done some very quick fitments just to get an idea of the final work, although there is still some more cutting and grinding to do before everything fits in perfect. hopefully that will be all done tomorrow. 2 Quote Link to comment Share on other sites More sharing options...
dr_broon Posted September 14, 2023 Share Posted September 14, 2023 Fair play mate. Coming along nicely Quote Link to comment Share on other sites More sharing options...
Dave Posted September 16, 2023 Share Posted September 16, 2023 Thats really quick progres your making mate. Nice to see the end sill plate/aarch panels are available. Think i'd be bricking it to cut out the rusty metal but best thing to do, will leave you with a totally rut free shell. Your grandparents would be well proud of the work your doing to save their car. Hats off to you mate, deffo following this build! 2 Quote Link to comment Share on other sites More sharing options...
Roverjoe Posted September 16, 2023 Author Share Posted September 16, 2023 Cheers, Dave! The idea is to just Cut out as much rust as possible, if in doubt cut it out! was a bit nerve racking at first making the cuts but once you get going its not too bad. and you can then just build from the ground up with fresh metal. 2 Quote Link to comment Share on other sites More sharing options...
Roverjoe Posted September 16, 2023 Author Share Posted September 16, 2023 Today I Didnt get much done thanks to the damp weather but i managed to get the end section of the inner sill sorted. there was a bit of rust that i was not happy with as it was heavily pitted. Its where the Bolt goes up into the chassis and is spot welded to the back of the inner sill, its Sandwiched between 3 layers of metal. The bush mounting section, then the inner sill then the inner arch. Honda didnt seem to seam seal that area!! so it was left for all sorts of crap to get in and to start rotting it. so i got it all cut out, grinded it to bare metal, then zinc and weld through primed the areas, fabricated a new piece to go in from 1.5mm steel and welded it in. Still need to Grind down the welds but ill do that when its a bit drier. 2 Quote Link to comment Share on other sites More sharing options...
Dave Posted September 17, 2023 Share Posted September 17, 2023 Weird Honda didn't seal that bit as it's where most of the crap/spray from the wheels lands! Loving your fabrication skills mate, looks so much better with that pitted area cut out and replaced with fresh steel. one less area to worry about now! Deffo inspired me to learn welding, might look at getting a course in the new year. Is it a mig welder you've got and are you using gas or gasless? Got so many ideas/jobs (not just for the cars, some stuff for the garden and garage too!) where being able to weld would be amazing. 2 Quote Link to comment Share on other sites More sharing options...
dr_broon Posted September 17, 2023 Share Posted September 17, 2023 On 9/14/2023 at 8:32 PM, Roverjoe said: Yeah i think thats the way to go in the future, i annoyingly broke a bumper clip, NLA for the Honda Part but plenty of Clips from a 45 thats probably 10x cheaper too. Just to show this, was just looking for some new bungs for my spare wheel well as a couple of mine have gone a bit gummy... https://www.parts-honda.uk/honda-cars/assignment_spare_parts/82871671000 £4.52 ex VAT from honda https://rimmerbros.com/Item--i-BNP4028 60p ex VAT for rover.. Quite a difference if you're buying the 10 that honda has as the default number for replacing them all! 2 Quote Link to comment Share on other sites More sharing options...
Dave Posted September 17, 2023 Share Posted September 17, 2023 8 minutes ago, dr_broon said: Just to show this, was just looking for some new bungs for my spare wheel well as a couple of mine have gone a bit gummy... https://www.parts-honda.uk/honda-cars/assignment_spare_parts/82871671000 £4.52 ex VAT from honda https://rimmerbros.com/Item--i-BNP4028 60p ex VAT for rover.. Quite a difference if you're buying the 10 that honda has as the default number for replacing them all! Lol I'm needing one for my spare wheel well too. Ta for the link mate! 1 Quote Link to comment Share on other sites More sharing options...
Roverjoe Posted September 19, 2023 Author Share Posted September 19, 2023 On 9/17/2023 at 1:01 PM, Dave said: Weird Honda didn't seal that bit as it's where most of the crap/spray from the wheels lands! Loving your fabrication skills mate, looks so much better with that pitted area cut out and replaced with fresh steel. one less area to worry about now! Deffo inspired me to learn welding, might look at getting a course in the new year. Is it a mig welder you've got and are you using gas or gasless? Got so many ideas/jobs (not just for the cars, some stuff for the garden and garage too!) where being able to weld would be amazing. Cheers and Yeah its a MIG welder, using Gas CO2/Argon Mix The Welder is a Parweld XTE171C and has been great to use so far! 1 Quote Link to comment Share on other sites More sharing options...
Roverjoe Posted January 6 Author Share Posted January 6 Blimey its been a while since i posted on here, I apologies for the lack of updates the car is still getting restored and such so dont worry i haven't scrapped it lol. Picking up from where we left off with the sills, i have managed to get that passenger side all completely welded now, I tried to make it look as original as possible by creating some panels to match that of the original. Here Was a piece that i had to make so that the Rear sill section could sit on top like it was done at factory, as you can see where the sills interlock with each other theres a part that goes under and a bit that goes over and it is then spotwelded together. I also remade the Rear Sill Reinforcer panel I didnt bother drilling a hole in it, its made from 1.5mm steel so it should be strong enough, for added strength i also bent the edges round like that of the original. Heres a bit of a Test Fitment not Quite there yet, a bit more bending! For the sake of doing the job properly i also drilled out the jacking point and made a new one from 1.5mm steel using the old one as a template! as you can see its a rust trap! Heres the new Jacking point, Drilled the holes out in the centre to match that of the orignal. Still yet to put the lip on it at the bottom where the jack sits on. Not the best welds, however they had plenty of penetration a bit more practise i think for when i do the other side, Heres a test fitment for the top bit as you can see from the other side i replicated that join where the two lower sills meet. Heres the Jacking point all welded on. I also got the Inner arch welded up, Shocking welding as the Metal quality of the original panels are crap it seems. thats what grinders are for i guess ;) I supported the sill with a block of wood to get the panels lined up, if your arches are intact youll probably notice there a small panel that joins the two together which i need to make sure is all in line as then itll be fixed in place once welded. Heres an example of the factory panel. Heres what i managed to achieve with limited metal forming tools. the panel was very complex to make as it features double curves and multiple bends. i had to make it out of two pieces then grinded it flush. The panel i welded in sits in a bit more than i had wanted it to, but thats not a major concern. a bit of seam sealer will cover up any imperfections. Now thats all done its time for the upper sill, I managed to get it all lined up and i zinc epoxy primed the inside of the panel Not the prettiest welding as i was filling 10mm holes with 1mm steel. hopefully ill get the hang of producing cleaner welds. but the main thing is that its all lined up correctly and im happy with the stiches i did either side. I got the grinder and grinded the welds flat and surprisingly the butt weld that i did was pretty much spot on. Here it is all in primer. The arch side was bit more of a nightmare as i was chasing pin holes, i reckon either some lead or filler will sort that out. with all the welding done for now, i got the sills waxed with Bilt Hamber Dynax S50 and completely flooded it I fit the door and sill cover back on and was pleasantly surprised to see how well the panel gaps are! 1 Quote Link to comment Share on other sites More sharing options...
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