a bit of this and a bit of that.

**mygasser** · 05-05-23, 09:34 PM

we sorted through the pile of bumper brackets that were dropped off with the rear bumper, the bumpers were off when he bought the car so he wasn't sure what was what. that was easy enough so next was which went which side and what way up. again it was straightforward so with some bolts in hand we fitted them to the bumper to find the next problem. the o/s outer one was bent forward missing the bumper hole by about 2". so we took the n/s off again and bent the o/s bracket to be a mirror image of the n/s. we then tacked the pairs of brackets together so the chassis end holes would stay aligned when they were bolted to the bumper. with the bumper supported on the super tall stands and a short pair on the workmate 'table' we could mark under the new floor where they sat and offer the new chassis parts up to make sure they would clear each other. all good.
we next moved to installing ('re'installing?) the box crossmember and the new chassis sections. while tapping the edges tight for welding we encountered another issue, some of the surface rust going forward on the bottom of the chassis wasn't..... surface that is. it revealed several pinholes which although they could be welded at this stage we'd just as well do some more checking and cut it away until we get to solid steel and fold up some pieces to add in. doh!
neil.

**v8pop** · 06-05-23, 08:33 AM

Coming on nicely Neil.

Cheers Tim W

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**mygasser** · 06-05-23, 10:10 AM

cheers Tim

**mygasser** · 09-05-23, 10:03 PM

the boot floor, new bits of rear chassis and rear valance are all fully welded now. no pics as it's like before with weld instead of cleco's.
neil.

**mygasser** · 11-05-23, 08:55 PM

today we made up the lower rear panel and filler neck to boot floor panels. the neck piece had to curve round and also the upright part wasn't, it sloped back of course. a bit of shrinking and stretching in the right order sorted it though. the rear panel has a lip to the floor and an angle on it's upper edge to tuck behind the lower bead of the original panel. on the zephyrs these 2 beads each side have chrome trim over them (consuls don't and zodiacs have a wash board over the whole panel) but we welded the holes for these as it's not having this or the side trim refitted. the 2 corners need making up and it'll look whole again, lol.
neil.
ps you can see my tube axle on the pallet under the zephyr too.

**v8pop** · 12-05-23, 07:54 AM

Looks well Neil, and the axle.

Cheers Tim W

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**mygasser** · 12-05-23, 07:45 PM

cheers, Tim

today we only got one corner done! a tiny area about 4 1/2" by 2 1/2" took 4 hours!!! mind you there's two factory joins, five folds, three curves (two of them compound), a rolled bottom edge and a bead all in that small area.

neil.

**v8pop** · 13-05-23, 08:11 AM

Looks impressive Neil, a good base for painting as well.

Cheers Tim W

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**mygasser** · 13-05-23, 11:20 AM

cheers Tim, still got the same again to do though

neil.

**40Stude** · 13-05-23, 05:27 PM

I'm always amazed at how you rectify the bodgery and fabricate the repair panels so accurately. Great to see.

**mygasser** · 13-05-23, 08:45 PM

thanks, years of practice i guess. that and having worked with good people and picking up stuff from them as i go along. i'm hoping my kids put some of what they're learning to good use too in the future.
today the other rear corner was done along with the extra extra chassis repairs forward of the last extra ones. we have bumper mounts and a small hole each side of the boot opening we noticed to do and the back end's done.
then to the front for the steering rack conversion and some small rust repairs on the strut towers.
after that it looks like the shell will go to be blasted (hopefully without uncovering any more trouble) so the owner can start body working it ready for paint. then we'll have room here to repair the door bottoms and he can have them too.
neil.

**Blackpopracing** · 13-05-23, 08:46 PM

Huge amount of work in that car now!
Looks excellent.

**mygasser** · 13-05-23, 09:30 PM

thanks mark, not too much to do now.

neil.

**v8pop** · 15-05-23, 07:44 AM

It's going to be a stunner when it's painted Neil.

Cheers Tim W

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**mygasser** · 16-05-23, 09:00 PM

hopefully mate, yes.
to day we finished up the rear end, yaaay. bumper bracket tubes welded in the chassis, boot opening rear corners welded, all the welding ground up underneath and finally a coat of 2k epoxy primer. the shell's almost done now, woohoo! oh, and we refitted the fuel flap to check bumper clearance.
neil.

**v8pop** · 17-05-23, 07:45 AM

Lovely job Neil.

Cheers Tim W

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**jsf55** · 17-05-23, 11:55 AM

Excellent work Neil

**taxirod** · 17-05-23, 05:28 PM

Great stuff Neil, are you painting it?
Or is it onto the next project for you now?

**mygasser** · 17-05-23, 09:13 PM

thanks all, we're pleased with it.
no paint for me ian, just the 'easy' stuff.

neil.

**v8pop** · 18-05-23, 07:44 AM

Originally Posted by mygasser

thanks all, we're pleased with it.
no paint for me ian, just the 'easy' stuff.

neil.

Ha ha

Cheers Tim W

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Thread: a bit of this and a bit of that.

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