Outer rear wing inspection

In order to start removing the patch welding from the Midget's boot floor I need to check the outer rear wing as I suspected that the inner wing repair was attached to the outer wing panel.

I knew there was some filler behind that paint! This explains why this section of the wing bends inwards that I will need to straighten somehow. I would think some sort of reversing mishap or a shunt from behind? Who knows

I have to say that I am quite relieved that this is the extent of the damage to the outer wing. I had imagined the filler and holes to be much higher than this. It will be much easier to retain the original shape.

Boot floor inspection

I can't believe I am actually writing this, but yes I have started to work on another section of the car... the boot!! (or trunk for my American followers)

This is a particularly challenging area of the car, so I will need to take my time. Certainly on the right hand side where some of the worst rust damage can be seen.

You can see some of the damage from underneath as well as from the top.

There was so many botched repairs that will make it harder to work out where the new metal should go. Speaking of new metal, I picked up the new panel from Moss, which is the biggest panel I'll have to weld in.

I have taken the decision to replace the whole floor. I just don't see the point trying to restore such a damaged section. So over the next few weeks I will be removing the patch panels and cutting out the rust and making way for this new panel. I seem to remember I will need to do a lot of spot weld drilling! Which reminds me I need to buy a new set of spot weld drills as mine are blunt!

Front lower repair for the rear wing

I've been looking forward to completing this repair for ages as it will finish off the right and side of my MG Midget. When I look back through my blog one of the first repair panels and welds I ever did was in this area (back in Dec 2013) and now I have completed this section. That's only 3½ years! Not bad going really...

First job was to check the repair panel for fitting.

Then I decided to paint those parts that would be hidden for a few years with chassis paint to protect from rust.

Then it was a question of welding the gap, but I felt that the gap was a little wide in places, so I cut up some metal to weld into place.

And then I stitched welded the gaps whilst making sure the alignment was correct.

It all seemed to ok, apart from the bottom right corner has lifted up a little so the gap wasn't even against the outer sill. This was caused by welding too much too quickly and causing metal shrinkage. So I had to make a cut into the repair panel near the bottom that would allow me to bend the panel so the gap was even and then stitch welded it. Lesson learnt!

I still have a little tidying up to do on the leading edge but I think it turned out ok. Also being able to tilt the chassis made my life so much easier.

An emotional farewell

It is with the greatest sadness that I have to say good by to my long serving, hard working tool mate, my Draper 79340 Multi Tool. 

Yes for some time now Drapey hasn't been feeling very well and developed a stutter that often resulted in poor running and sometimes even stopped completely, until one day he went bang!

Oh well, time to upgrade and meet my new Dremel 3000!!!

Looking forward to some serious precision engineering!!

Footwell End Panel Repair - Completed

Finally finished off the footwell end panel. I found this repair particularly challenging as you have to lean across and right down into the footwell to do the welding. It is also hard to brace the panel in place, as you cannot clamp it, so I braced it with wood against the cross-member on the floor as best I could, but I found the panel didn't make perfect contact at every point so some of the puddle welds kept popping off and needed re-welding. But we got there in the end.

Small Victories

Every once in a while something on the project gives me a real boost of motivation. The other week I bought the sill end cap which is designed to close off the inner sill from dirt of water coming in from the wheel arch. With all the cutting out of metal and potential twisting of the chassis and with no real experience in restoring an MG Midget I was so happy to find that it slotted in perfectly!

A-Post Repair - continued

Now that I have finished the A-post repair I have to say it has been extremely challenging to get it to fit correctly so that it makes the door and wing gaps look half decent.

Offering up the new repair panel seemed to suggest all was well.

 

Getting everything in line and moulded into shape took a lot of time.

After a lot of checking and double checking, welding, grinding and more welding I offered up the front wing to check the gaps.

You might be able to see the gap at the top of the wing widens right where I have welded the new panel to the original A-post. At first I wasn't sure if this was the wing or the A-post. I couldn't understand why the gap was there as the original metal curves in as well.
This meant I had to put a whole load on new metal to rebuild the apex of the curve.

But we got there in the end. I have also improved the gap between the door and the a-post so it is even all the way down, especially around the corner.

One of the final jobs was to crimp the flange into place. A pair of pliers and a block of wood was called for.