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Bugeye rust repair with some crash damage.

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pinkyponk Avatar
pinkyponk Gold Member Adrian Page
Berwick, NS, Canada   CAN
My spot welder came from HF. It's the 220 volt model. It weighs 30 pounds I think. Very heavy. It does do a good job but it wouldn't run off the extension cord from my generator. I had to buy an 8 gauge(!) cord for a welder. It's thicker than a garden hose! Spot welders are very sensitive to voltage drop from extension cords.

I sat the welder on a foot stool to do the little patch I showed in the last post. I really think remote tongs is the answer. The clamping force does not need to very high. In fact too tight a clamping force will give you poor welds and causes the tongs to stick to the welds. There is a bit of an art to running a spot welder. (not much... but a bit)

I plan on spot welding the sills in so I will be forced to find a solution fairly soon.

Thanks for the depth reading. I really need a pattern for the shape pressed into the pan. It's a shame we don't have all the data Barney has gathered for the MGA crowd.

Adrian



Home built Eaton M62 Supercharger with 9psi boost, "stock" high ratio rocker arms, 8:1 compression, Piper 270 cam, ported head, matched manifolds, CB Performance computerized ignition.



Edited 1 time(s). Last edit at 2018-01-31 09:10 PM by pinkyponk.

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ice Avatar
ice Gold Member Larry Ice
Lawrenceville, GA, USA   USA
Let me see what I can do for more measurements. Won't be able to pass them along til this evening though. The shape of the depression is really a bit complicated unless you have some type of press. On the drivers side of my 71 I just made the floor flat and it works fine. The 67 I did the same thing, both the 67 and the 71 I used SS to replace the floor boards.



Iceman

Atlanta GA

60 AH MK1
62 AH MKII
67 Midget
71 Midget

pinkyponk Avatar
pinkyponk Gold Member Adrian Page
Berwick, NS, Canada   CAN
That would be great Larry! I won't be needing floors for a quite a while so no rush. I haven't figured out how to make them but it must be possible. I think I can do it with some sort of hammer form. I do have access to a pretty big press if it comes to that.

Adrian



Home built Eaton M62 Supercharger with 9psi boost, "stock" high ratio rocker arms, 8:1 compression, Piper 270 cam, ported head, matched manifolds, CB Performance computerized ignition.

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pinkyponk Avatar
pinkyponk Gold Member Adrian Page
Berwick, NS, Canada   CAN
I cut away the rest of the rocker panel and test fitted the new ones from Ashley Hinton. They seem to fit the space nicely. The only thing I've noticed so far is the flange at the front where it welds to the side foot well panel is about 1/4" less width. Won't affect anything.

I think I'm pretty much stuck now until I can get the A post repaired or find a new one. Otherwise I can't see how the door will fit.

Adrian



Home built Eaton M62 Supercharger with 9psi boost, "stock" high ratio rocker arms, 8:1 compression, Piper 270 cam, ported head, matched manifolds, CB Performance computerized ignition.



Edited 1 time(s). Last edit at 2018-01-31 09:11 PM by pinkyponk.


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pinkyponk Avatar
pinkyponk Gold Member Adrian Page
Berwick, NS, Canada   CAN
Finally got back to work on the A post. I decided to make a patch and use as much of the original part as I could. I removed the remains of the A post and developed a pattern for hammer forming a new piece. The post had been damaged in an accident and was pretty bent up. It also looked to me like it had a "portapower" dent in it from someone "enlarging" the door hole. I managed to get the dents and bends out. Amazing what you can do with a hammer and patience.

I used MDF based on favorable reports on this site. It works great... very hard and keeps it's edges even under vigorous hammering. I bent a 1/2" flange along one side and clamped the piece between the halves of the form with lots of clamps, then carefully hammered it over with a dead blow hammer. I found it developed a wave from the bending that had to be worked out by shrinking with the rubber hammer. I "gathered" the extra material by moving the clamps closer together on either side of the wave and hit it to drive it down. Worked fairly well. The part got a bit of a curve along the bottom on the curved side from the wide curved flange so I flattened the bottom of the part with a drift on my anvil. Just hammered along the corner, using the drift as a punch.

I used remnants of the original part to figure out where to cut the patch so it would fit up and end up the correct length. Then I cut it wrong (too short) and started over. (repeat above steps) The new part was cut properly and tacked in place. Fits really nice. Next step will be making a new hinge plate bracket and drilling the holes.

Adrian



Home built Eaton M62 Supercharger with 9psi boost, "stock" high ratio rocker arms, 8:1 compression, Piper 270 cam, ported head, matched manifolds, CB Performance computerized ignition.



Edited 1 time(s). Last edit at 2018-02-14 02:11 PM by pinkyponk.


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ice Avatar
ice Gold Member Larry Ice
Lawrenceville, GA, USA   USA
Looks good, one can see lots of work going into the car!



Iceman

Atlanta GA

60 AH MK1
62 AH MKII
67 Midget
71 Midget

Yankeedriver Avatar
Yankeedriver Platinum AdvertiserAdvertiser Joel Young
Albuquerque, NM, USA   USA
Pretty neat! I have used MDF for years for making furniture (stable base for vacuum-applied exotic wood veneer) and ultra-stiff/durable boxes and anti-torsion platforms (my 6' router table and planer/miter saw stand), but never for this. Great idea and nice results!

Joel


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pinkyponk Avatar
pinkyponk Gold Member Adrian Page
Berwick, NS, Canada   CAN
Got a little more work done. Lots of fitting and leveling and fretting before I finally welded in the inner rocker panel. I had to make an outer footwell panel that required a joggled edge. Picture shows how I did it. Then I had to figure out the shape of the toe board from pictures on the internet. More test fitting and I also re-leveled the car, checked everything again and then spot welded in the rocker panel. I like my spotwelder!

Adrian



Home built Eaton M62 Supercharger with 9psi boost, "stock" high ratio rocker arms, 8:1 compression, Piper 270 cam, ported head, matched manifolds, CB Performance computerized ignition.



Edited 1 time(s). Last edit at 2018-02-24 06:54 PM by pinkyponk.

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Perdido Avatar
Perdido Gold Member Rut Rutledge
Tuscaloosa, AL, USA   USA
What? No pictures of you one handing the spot welder and taking pictures with the other? Those are hefty little buggers aren’t they!
Rut



1960 Bugeye undergoing restoration, 1275
1970 MGB, Pale Primrose
1967 Triumph TR4a
1966 Triumph TR4a
When I went to school, they asked me what I wanted to be when I grew up. I wrote down 'happy'. They told me I didn't understand the assignment, and I told them they didn't understand life. John Lennon

pinkyponk Avatar
pinkyponk Gold Member Adrian Page
Berwick, NS, Canada   CAN
You got that right Rut! I had to quit and take a nap after doing that many! I ate a big breakfast this morning and I'm heading back out for some more one handed spot welding.

I need to fab up a set of remote tongs for that bad boy. I did make a set of vice grips into a joggler yesterday. I had to joggle a flange in place on the car. I'll post a picture later.

Adrian



Home built Eaton M62 Supercharger with 9psi boost, "stock" high ratio rocker arms, 8:1 compression, Piper 270 cam, ported head, matched manifolds, CB Performance computerized ignition.

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rhodyspit75 Avatar
rhodyspit75 Ernie Connor
Cumberland, RI, USA   USA
I had borrowed a spot welder from a friend and the cheap plastic sw broke soon after. I pulled it apart and spliced thevswitch wires together. I made up a foot switch for it and it’s so much easier to use. I can now position it with both hands and just step on the switch.

pinkyponk Avatar
pinkyponk Gold Member Adrian Page
Berwick, NS, Canada   CAN
Good idea Ernie.

Here are the joggle pliers I made from some damaged vice grips. Primitive but functional.

Adrian



Home built Eaton M62 Supercharger with 9psi boost, "stock" high ratio rocker arms, 8:1 compression, Piper 270 cam, ported head, matched manifolds, CB Performance computerized ignition.


Attachments:
joggler 001.JPG    29.6 KB
joggler 001.JPG

Yankeedriver Avatar
Yankeedriver Platinum AdvertiserAdvertiser Joel Young
Albuquerque, NM, USA   USA
In reply to # 3686818 by pinkyponk Good idea Ernie.

Here are the joggle pliers I made from some damaged vice grips. Primitive but functional.

Adrian

Pretty neat 'roll yer own' tool, and you saved $35~50, too. This Gepco tool is at the lower end of that range. No idea about quality.

Adrian, I'm learning so much about metalworking watching this thread. I'm now reconsidering a host of subtle but cool bodywork cues that I wouldn't have thought possible without huge dies, etc.

Much obliged.

Joel



Edited 1 time(s). Last edit at 2018-02-25 10:30 AM by Yankeedriver.


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pinkyponk Avatar
pinkyponk Gold Member Adrian Page
Berwick, NS, Canada   CAN
Joel,

If I had any "plan ahead" abilities I would have just bought one... but I don't... and I needed the joggler. You can buy a nifty air powered joggler that also punches holes. My next trick will be attempting to make the pressed floor pans with hand tools. grinning smiley

Some of the most fabulous cars ever made were hammered out with mallets on a tree stump.

Adrian



Home built Eaton M62 Supercharger with 9psi boost, "stock" high ratio rocker arms, 8:1 compression, Piper 270 cam, ported head, matched manifolds, CB Performance computerized ignition.

Yankeedriver Avatar
Yankeedriver Platinum AdvertiserAdvertiser Joel Young
Albuquerque, NM, USA   USA
In reply to # 3686858 by pinkyponk Joel,

If I had any "plan ahead" abilities I would have just bought one... but I don't... and I needed the joggler. You can buy a nifty air powered joggler that also punches holes. My next trick will be attempting to make the pressed floor pans with hand tools. grinning smiley

Some of the most fabulous cars ever made were hammered out with mallets on a tree stump.

Adrian

I love it... my wife laughs at me for making bolts out of all-thread or shortening longish ones and cleaning them up with a die, rather than driving into town. Same affliction, I guess. But if we were into ready-made-landia, I guess we wouldn't be working on 50-year-old British hot rods. smileys with beer

Joel


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