1970 Rover 3500 - EMF

Leading on from the last pic of the B post last weekend I cleaned off the Epoxy Mastic and set about closing that section off.



I've left drain holes and also decide not to replace the sides at the bottom where it meets the sill so it will be easy to paint, apply cavity wax and dry out if it needs to.



I did the same for the rear jacking point, although I've still got to make and fit the curved section that finishes off the bottom of the wheel arch.



I've test it using the Rover jack and it works perfectly - no flexing or creaking.
 
testrider said:
I've still got to make and fit the curved section that finishes off the bottom of the wheel arch.
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Here is said section welded in place and smoothed off awaiting the Epoxy Mastic. I reckon that took about 5 hours to make and fettle to fit the hole.



Here is is from inside the wheel arch together with the closing panel that took about 3 hours to make!



This just left the bottom of the front jacking point to finish off which completed the sill replacement project. Note the etch primer running out of the drain holes.



I should probably do the other side at some point!
 
I remember very well Paul, doing that to my 2000, hopefully to as good a standard as you're doing.

It's nice to know that underneath all the panels the car is 'right' :D
 
Thanks Phil. I could have put a flat plate across that and trimmed it off to clear the end of sill cover, but it didn't feel the right thing to do like you say.
 
testrider said:
I should probably do the other side at some point!
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Erm, yes, that was a while ago and I didn't think it was that urgent at the time because the passenger side sill looks like this.



Patched, but much better welding than the drivers side. However, a bit of digging at a suspect lump inside the rear wheel arch left this.



It's only the outer bit of the jacking point though so it'll be fine - wrong!



Plenty of grot on in the inside under the carpet too plus some suspect older 'repairs'.





Only one thing for this - open a fresh box of cutting discs and gets started.



I think I might have to cut a section out of the D post to get to this bit though so it won't be a cheap repair this time.



I'm going to ignore that for now and start at the front though.

Just like on the telly for added peril :shock: and excitement :LOL: I've got a self imposed deadline, I really want it done for the Silverstone Classic at the end of July. :roll: :cry:

More to come soon.
 
Ooh, that really is quite rotten :shock:

Gotta be ruthless in the battle against rust. Better to get it now than let it go another season. You'll be glad you did it. Be interesting to see how deep that goes into the D post. "Much deeper than you think" as Tim Vine would say :LOL:

Dave
 
Quagmire said:
Argh! You'll have it done in no time, you're a dab hand at this by now! :LOL:
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Thanks Jamie, I'm also getting a bit bored of it too. Feels like I've been cutting, welding an painting for about 4 years! Anyway it'll not need doing again once I'm done.

Dave3066 said:
Ooh, that really is quite rotten :shock:

Gotta be ruthless in the battle against rust. Better to get it now than let it go another season. You'll be glad you did it. Be interesting to see how deep that goes into the D post. "Much deeper than you think" as Tim Vine would say :LOL:

Dave
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I actually got some sill sections made up last year when I did the other side, but there no where near big enough this time.
 
It's been a while since I updated this thread, but I've been busy chopping and welding and had a holiday thrown in for good measure.

I decided to start at the front with the inner sill and floorpan repairs. Previously the floor pan had been dented in so I bashed it out, but I had no reference points as the sill was non existent so I had to do a best guess of where it went.



This first bit was tricky as it had a curved flange in the inside to connect to the floor.



I also decided that I wanted to keep the factory production line pressings, the front one was too far gone so I made a new one - the original bracket was plug welded on later.



Gradually working along the inner sill - here you see the indent for the front seat mount.



If ever anyone needed proof as to why we cut rot out before welding in new steel, here it is. You can see how the rust has transfered to the new metal.



Then there was this little lot to sort out.



I may have slightly cocked up the measuring on this one.



New jacking point fabricated.



Plus some repairs to the front one.



This is my press tool that puts the stepped edge into the sill section. It's made from ¼" plate welded together with some nuts and threaded bar for a pivot.





Here's the new sill in situ, stepped edge is underneath and replicates the factory spot welded seam even though I've seamed welded it.



Rear jacking point boxed in and the inner wheel arch repair started. Ready for the D post section to go back on (no photos of that)



Last bit to finish it off is the oval pressing on the front splash panel.



Last month I said:-

testrider said:
Just like on the telly for added peril :shock: and excitement :LOL: I've got a self imposed deadline, I really want it done for the Silverstone Classic at the end of July. :roll: :cry:
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Well, I covered it in Epoxy Mastic yesterday and it looks great. I fitted the interior back in before breakfast this morning and dropped it off at the local garage for an MOT at 9:30. Just waiting for the phone call with (hopefully) good news.........
 
Just had the call and it's passed so we're all systems go for Silverstone on Saturday! I need some sleep now.
 
testrider said:
This first bit was tricky as it had a curved flange in the inside to connect to the floor.

Click to expand...

Nice bit of shaping going on there Paul. Love your tool for stepping :D. Mine is a bit more rudimentary in the form of a step in my homemade metal folder that is just the right depth to knock in a step with a blunt chisel.

Good work on EMF and congrats on the MOT pass :D

Dave
 
Thanks. I couldn't curve that flange without snipping and rewelding though, I tried shrinking it with the hammer but to be honest I got bored and nowhere near the right shape. I think a dedicated shrinker/stretcher tool would have done that in a couple of minutes though.

I also forgot to add that to shape the stepped edge you need an assistant to hold the other end of the sill. :D

Dave3066 said:
Be interesting to see how deep that goes into the D post. "Much deeper than you think" as Tim Vine would say :LOL:
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There are still some crusty bits in the seam that goes around the rear wheel arch that I didn't have time to cut out, but I have an MOT and the sun is shining - and I can't see them now either so for the time being they don't exist!
 
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