Gilfy Restoration: Starts here...

bighed · Posted: Tue Apr 22, 2014 5:33 am Post subject:

Gutted I'm not nearer as would live to see one in the condition yours is in. Then seeing the end product.

Good work!!! big grin

DeadEye · Posted: Tue Apr 22, 2014 12:50 pm Post subject:

DeadEye · Posted: Tue Apr 22, 2014 8:01 pm Post subject:

So, finished off the patch for now - the big plug welds can wait until I get it spot welded as the guy has a bigger welder. I'll spot-weld the floor to the sill at the same time.

I've still got a patch to repair on the driver's side but Gilfy is pressed up against the wall that side so I can't really do anything until he's mobile again - which means the front end needs to be full welded up.

So the next step IS to weld up the inner wings, front chassis and bulkhead which means I need some cash first...

DeadEye · Posted: Tue Sep 02, 2014 12:34 pm Post subject:

Ok, back again.

Got the front up on the workmate so I can get underneath. I want to get the lower bulkhead treated and ready for when the font end is spot-welded and I can get the front suspension back on to make it rolling again.

While angle grinding the stone chip off the angle grinder was too close to my nuts for comfort!

You can see the welds from underneath now - seems to have penetrated through ok.

Upper part already epoxy mastic'd from when I did the front chassis:

DeadEye · Posted: Tue Sep 02, 2014 12:38 pm Post subject:

Now time to get some suspension parts cleaned up.

Mingy:

Mingy:

One down:

All done

DeadEye · Posted: Tue Sep 02, 2014 12:40 pm Post subject:

Etch prime them for now:

Looks like I might be taking these to be power coated now... Probably wasted my time but hey, at least I wasn't hoovering.

DeadEye · Posted: Tue Sep 02, 2014 12:41 pm Post subject:

Managed to get some new bushes, just got to ram these feckers in the holes somehow!

I think the chap opposite must have a press.

DeadEye · Posted: Mon Sep 15, 2014 4:23 pm Post subject:

A new bit - surprised to find they were Brembos

DeadEye · Posted: Mon Sep 15, 2014 4:28 pm Post subject:

Hmmm knackered:

DeadEye · Posted: Mon Sep 15, 2014 4:33 pm Post subject:

Should be a bit easier to undo than the original was...

DeadEye · Posted: Wed Sep 17, 2014 8:06 pm Post subject:

So, been buggering around for a couple of days trying to master the plug weld as I'm just plane stalling waiting for the spot welder fairy to turn up.

Could not get the penetration I needed to be confident until finally, I increased the wire size to 0.8mm and used the spot weld dril bit to just cut into the thicker base (chassis leg).

Finally, I had to ruin my bit of sheet to tear it:

Very happy, finally I can trust the plugs!

DeadEye · Posted: Wed Sep 17, 2014 8:19 pm Post subject:

So, time to bite the long-awaited bullet!

Bloody batteries ran out on my drill so only got these drilled:

Ironic that I spent months and months removing spotwelds with a fecking spot-weld removal bit, only to use the same bit to drill the holes for plug welding.

Ready for first one!

A genuinely exciting and nerve racking moment

First one of many

All done - I lost one though, the hole was a bit high

Surprisingly little to grind back

Plenty of heat the other side:

What plug welds? By the time I sand blast the area, prime, stone chip etc, you won't see anything.