On The Side Again...

Got out for a few more hours today, but its very cold! I wrapped up warm and got as close to the halogen lights as possible, which made it actually quite pleasant.

The outer sill needed closing at either end, and the bottom needed folding over and welding. I didn't get anywhere near as much as i wanted to done, again. The front closing panel was not even close to fitting and access was bad, so i decided to roll the shell back onto its side. This gave me a good chance to have a clear up too - I'm moving House in a few months, so this is essential!

The front closing panel was so far from fitting i decided to make my own. I took a small piece of stock steel and cut it to a similar size. I tacked it into place on the front of the sill, but on the outside not the inside like the proper panel.

I took a stretching hammer from my new panel beating kit and tapped the metal in to the correct curve, using the out sill curve as the dolly. This was very effective. I then plug welded, through some previously punched holes, the panel onto the outer sill.

Some more beating and shaping and the piece had a reasonable curve from the outer sill to the foot well, where it was plug welded again. More beating smoothed it all out and i seam welded the patch in place.

About half an hour with the grinder saw it smooth and shapely. A coat of primer finished it off. Not bad for an afternoons work, and my first use of the panel beating kit.

With the car on its side again, it was a good time to take stock of the progress I've made. It makes a good picture to see one new half and one old!

Slow progress...

Today was a very frustrating day in the garage. Nothing went my way! First of my MIG was playing up, it seemed to have wire feed issues and was "pulsing" the wire. Not sure what it was, but the tip seemed to be catching the wire, so i replaced that, but the replacement melted! It then melted a second, but the third survived. Good job i bought a 5 pack!

The wire feed issues continued until i ran out of gas! Last time i bought a C02 Argon mix, and it really hasn't lasted very long at all compared to plain C02. After getting some more gas it all seemed to sort itself out. The wire ran smoothly and the C02 made a much nicer weld than to C02 Argon mix.


Now that i was finally underway, i tackled the outer sill. After several trial fits and aligning it to the door and wing i tack welded then plug welded the top section to the inner sill and the footwear side.

I decided to seam weld between the plug welds on the foot well side, it seemed like a good idea and i just thought the plug welds wernt that strong. Some have said that seam welding the sills is a bad idea as they actually act as crumple zones in the event of a crash. My thoughts are its a 36 year old car made when crumple zones wernt even thought of and if i crash it, i want it to stay in one piece. I could be wrong, but i dont intend on finding out!

So with the top of the outer sill firmly in place i need to work out how the bottom of it should be attached. It has a lip that could either be folded around the inner sill and welded, or i could cut it off in order to get clearance to punch holes to plug weld it on. Ive asked a question on the MG BBS to find out what others have done.

Hopefully ill get out again this weekend and make more progress.