Heelboard repair

Firstly a bit of a hole.

After a CAD drawing.

Trial and error.

Tacking in place.

Now time to grind off the welds.

Floor pan door step and flitch. 2

Door step is welded in place.

Flitch plate is welded in but weld still needs grinding down.

Floor plan welded in ..

Drivers side floor pan toe board and instep.

Driver side (LHD) floor pan door step and flitch panel removed .

New door step line up..

One big hole.

Another trial fit..

And now tacking in.

Tack tack pzz pzz and its all going in their,,

Flitch plate has now been spot welded in..

Floor plan tacked in also already for welding in defineatley.

Door skin and sill.

Inside door skin coated in wax treatment.

 Outer sill all plug welded on by Owen.

 Looking nice Owen well done.

Passenger side outer sill

Taped off and sprayed in a coating of wax protection helping against rust.

After a fairly thick layer of wax protection and 12hr later the wax was pretty much dry.

Whilst I was dirtying the spray gun anyway I thought I would coat the inner door skins

 and outer sills leaving an area coated in weld through primer along the seem .

Outer sills were drilled ready for plug welding and the area cleaned

where the sills were to be welded. 

Owen cracked on with the preparation.

Flitch plate welded in ..

Inner sills rust prevention treated. Now wax anti rust..

Flitch panel put in place ready to weld. It just shows the manufacturer of these replacement panels has drilled the holes for the door hinges slightly of centre.

I also need to weld in a strip between the flitch and the body.

Everything has been prepped and sprayed in INOX Spray (weld through primer).

Starting to get somewhere !

Shame about the strip that has to welded in..

Well flitch panel prepped full with holes ready to clamp in place and plug weld.

Door post/jam cleaned ready to be welded rust free and sprayed with Inox spray (rust through primer)

Inbetween where I will not be welding also has zink spray on it and primer to help against future  rust.

And just at the wrong time is my grinder knackerd, probably the carbon brushes.

Damn....... Bosch pro 170 euro !

Sunday evening was a bit of a tidy up in the garage and also getting the 

metal prepared where the new Flitch panel will be fitted..

Today we took on a little  job I think may be a good idea... 

Maybe you think its not such a great idea ?

I though it may be a help against future rust to remove all the transit paint from the new panels

 and cover the inside of the  panels in a red anti rust primer including windscreen corner panels left and right. Here is Owen removing all transit paint with the wire brush attachment !

Also I thought it would be a good idea to use weld through primer (Inoxspray from Mahotec)

http://www.rustbuster.nl/Aanbiedingen/Inoxspray.htm

On all seems that were going to be mated together and plug welded.

The wire brush attachment works prety good on the cordless drill.

Nice and light ideal for 14 yr olds who are helping.

Outer sill transit paint has been brushed off the inside of the repair panel and painting comences with the anti rust red metal primer.

Owen in action and working really well ...

Meanwhile Liam and his sister Vienna started doing the inside of the A-Panels.

Nice one Liam what a good job son.

Liam is also giving the windscreen corner support panel a lick of paint too.

Once again the parts that are to be welded get sprayed in inox spray.

What the boys can Louis can too !

Good girl Vienna !

Looking great kids thanks for your hard work..

Here are a couple of Vlogs i like watching and getting inspiration from !

https://www.youtube.com/watch?v=YFxWB84b1Ok&t=190s

https://www.youtube.com/watch?v=2sUjePEeAAM&t=5s

New floor plan placement and tacking (plug welding).

 Started to look like a floor pan again now..

Just a case of welding further grinding and wooopa..

Time for the task of floor plan replacement !

Got the large can opener out and snip snip...

 Flitch panel replacement comes hand in hand with floor panel.

This one has been repaired  doesnt look to bad but the inside it has a fair amount of rust, it is better to replace now whilst I have the choice !

 Here i have had a bit of a trial fit and it isnt looking to bad !

Under the mole grips someone has had a bit of a repair and I think I am going to replace that too.