Well, as many may know, I have recently discovered that my lower radiator cross member has finally succumbed to the dreaded tin worm.

Hopefully, this is day one of my journey to successfully repairing it with a suitable replacement.

Wish me luck, I think I will need it.

 

So, today I started the dismantling of the front end, and within a couple of hours I had removed the front bumper etc'

This was done on the driveway, and I hope to complete the rest of the work in the garage, hopefully.

 

I have reached the point where I am unfamiliar with most of the critical items that now stand in my way, and would seriously appreciate some advice as to how I should proceed.

 

First question/concern that springs to mind is... Can I continue successfully with the car being in the garage?

The last thing I want to do is get half way through the strip down only to find that I do not have the correct access.

The car is drivable at the moment, but once I start taking various parts off she will become immobile.

 

Your help and advise would be very much appreciated.

 

Please see photo's attached...

Edited May 29, 20169 yr by redwine300

Ran my set up welds tonight, my god I am out of practice.

Anyway, I decided to start at the lower end of my mig and work up monitoring the weld height and penetration as I went.

Here's the results, no laughing please.....

 

Starting from left to right....

(Clarke 135te turbo machine)

 

First, power at 1 min, wire feed at 5. (poor penetration and spitting/burning back)

Second, power at 1 min, wire feed at 5.5 (as above)

Third, power at 1 min, wire feed at 6 (as above)

Fourth, power at 2 min, wire feed at 6 (as above)

Fifth, power at 1 max, wire feed at 6.5 (as above but with buzzing)

Sixth, power at 1 max, wire feed at 7.5 (better penetration, some spitting)

Seventh, power at 1 max, wire feed at 8 (better penetration, less spitting)

eighth, power at 2 max, wire feed at 8.5 (fair penetration, some buzzing)

ninth, power at 2 max, wire feed at 8 (as above, probably should have tried a wire speed of 9)

tenth, power at 1 max, wire feed at 8 (good penetration, some crackle and some spitting)

eleventh, (as above)

 

If the welders amongst you would cast your eye over these and make suggestions as to how to improve things, I would be greatful.

6 7 8 looks spot on...would be even better with the mill scale ground off too. 10 11 looks like it has good heat/penetration but needs more wire to match.ide go with 678 and get the job done:yes:

6 7 8 looks spot on...would be even better with the mill scale ground off too. 10 11 looks like it has good heat/penetration but needs more wire to match.ide go with 678 and get the job done:yes:

 

Cheers znut, I think I will run some more trials along the lines of 678 as you suggest.

Thanks. :thumbup1::thumbup1:

WELL??????

Is it finished yet?

lol.....

How's it going mate?

Have you got back into the swing of welding?

Decided to finish off the repair as I have almost given up on a replacement.

Just hope that my welds are strong enough.

Stop stressing over those few loose spot welds matey...the strength of the part is in its folded construction,the spot welds are just to keep the folds together otherwise it would of been seam welded at manufacturing.Have you drilled the spots and re-welded?? thats all it needs;)

Decided to finish off the repair as I have almost given up on a replacement.

Just hope that my welds are strong enough.

 

Fantastic stuff Dave! Great to see it all done properly!

Stop stressing over those few loose spot welds matey...the strength of the part is in its folded construction,the spot welds are just to keep the folds together otherwise it would of been seam welded at manufacturing.Have you drilled the spots and re-welded?? thats all it needs;)

 

Thanks for the reassurance znut.. :thumbup1:

Yes, I drilled out from one side of the spot welds and re-welded.

Fantastic stuff Dave! Great to see it all done properly!

 

Thanks Si, appreciated. :thumbup1:

Thanks for the reassurance znut.. :thumbup1:

Yes, I drilled out from one side of the spot welds and re-welded.

 

Now get in in the shell and do some more welding.

Like Bri says .... stop stressing ....get welding.:yes:

Stop stressing over those few loose spot welds matey...the strength of the part is in its folded construction,the spot welds are just to keep the folds together otherwise it would of been seam welded at manufacturing.Have you drilled the spots and re-welded?? thats all it needs;)

 

Agreed.

I know, I know, it's not welding, but you have to admit, putting the first layer of paint on is pretty cool. :yawn:

Finish coat added, and no runs! :biggrin:

All you need now is a display case!

Looks all clean sweet and dandy but you dont want paint on the inside of holes were your going to weld and all that hard work is going to get burnt too then need painting again:confused:

All you need now is a display case!

 

:lol:

Just finished my first final fit before prep and weld and noticed that the left hand side remained vertical, but the right hand side is slightly distorted.

Can not see how to correct it..

Looks all clean sweet and dandy but you dont want paint on the inside of holes were your going to weld and all that hard work is going to get burnt too then need painting again:confused:

 

I agree znut, :thumbup1: I guess I was just doing as much up front as possible in the hope of a replacement, but I think I will have to go with this one.

I will heed your advice and clean away the paint locally on each weld point before I start welding.

I know I will make a mess of the paint locally, but I am prepared for a tad of dressing and touching up post welding.

Just did not fancy finish spraying the whole thing in situ either, not with my history of overspray. :blushing:

Edited July 2, 20169 yr by redwine300

You just need to pull the new crossmember in tight to the frame rails using some clamps before you weld that's all.

 

But come on FFS get welding! Summer is on it's way out! :lol:

You just need to pull the new crossmember in tight to the frame rails using some clamps before you weld that's all.

 

But come on FFS get welding! Summer is on it's way out! :lol:

 

:confused1: sum mer?

:confused1: sum mer?

 

Touché

One step nearer the welding now that I have waxed the inside.

Well after a couple of more hours loosely fitting everything up, I finally managed to start welding.

First 3 seemed to go okay, if not slightly off center.

Welding continued...

Welding continued...

Good stuff.:thumbup1:

Dont forget to brush some seam sealer round all the seams before you start painting.