MK1 Rover 200

MK1 Rover 200

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Liquid Knight

Original Poster:

15,665 posts

140 months

Tuesday 3rd January 2012
quotequote all
Balmoral Green said:
'New Year, New You, Exercise Class'.

A gentleman always exercises class smile
That's junk mail. I'm a personal trainer in my spare time. wink

After a spot of lunch I cut the hole out of the floor...



...as much rust out as possible and I salvaged the jacking point so I can either make another or restore it...



..welded the plate in place from inside the car (with the door closed so the rain kept out)...



...not the tidiest of jobs but it's done.

I got underneath the car to start preparations to fit the sill patch when I was interupted again...





Looks like a shower so I'll have a coffee and get back to it.

Edited by Liquid Knight on Tuesday 3rd January 14:25

VinceFox

20,566 posts

129 months

Tuesday 3rd January 2012
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I can't get over the amount of effort you're putting into this type of car.

Liquid Knight

Original Poster:

15,665 posts

140 months

Tuesday 3rd January 2012
quotequote all
Thanks. I need the car for when it's foggy and not safe to cycle to work. Cars like the Rover SD3, Montego, Nissan Bluebird and Ford Sierra are the unsung heros of the 80's in my opinion. Okay Deltas won Rallys and RS500's won the BTCC and everyone remembers iconic cars like the E30 M3, SD1 and 205GTi but it was the bread and butter cars like my Rover and the others that kept the country moving and have all but forgotten.

Anyway back on topic. Before I start humming the New World Symphony. wink

I needed to trim about 2mm off of the lip I welded on yesterday because I had made it straight and the end of the sill curves slightly. Bloody three box car with a curve where you least expect it. silly

First trail fit of the sill patch...



...and it's just a case of cleaning the surfaces ready to weld in place. Due to the unexpected curve I'll have to clamp and weld half an inch at a time and talk it into fitting I recon. wink

Liquid Knight

Original Poster:

15,665 posts

140 months

Tuesday 3rd January 2012
quotequote all
The rain eased again and I thought I'd exercise a little Norfolk Health and Safety...



...a quick coat of Hammerite inside...



...before I welded the sides and top of the sill patch in place.



I then managed to set fire to myself a few times welding the lip of the sill patch to the lip I welded in plase yesterday. Also welded the underside of the floor plate. Got cramp in my neck a few times. Set fire to myself again and decided to call it a day (night).

A quick coat of Hammerite to protect the new metal overnight and all I have to do tomorrow is mount the jacking point and paint the whole of both sills so it looks half way tidy-ish.



Thank you for all the comments, support and constructive critique. Let's hope that's good enough for the M.O.T next month. smile

MGJohn

10,203 posts

140 months

Wednesday 4th January 2012
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LK ~ You're quite good at this .. All power to your wossnames.. smile

Liquid Knight

Original Poster:

15,665 posts

140 months

Wednesday 4th January 2012
quotequote all
Just ground the outside welds a little flatter and another quick coat of Hammerite only for the wind to swing and cover my face with the stuff. Bleaugh! Lucky I was wearing goggles.

Liquid Knight

Original Poster:

15,665 posts

140 months

Wednesday 4th January 2012
quotequote all
Just had a look at the M.O.T certificate thinking I would need to book the car in at the begining of next month. Nope. It runs out Friday! yikes


Liquid Knight

Original Poster:

15,665 posts

140 months

Wednesday 4th January 2012
quotequote all
As well as discovering the M.O.T is due this week instead of next month I have made another discovery. More about that later. The current M.O.T gave me an advisory notice about the end of the sill on the drivers side and the passenger side front jacking point so I set about making a new pair to weld on the new patch of floor and up front.



I'm using an off cut of 2x1 rounded box I have in my shed.



Old and new after about an hours work for the pair.



Drew around the jacking point inside the car an drilled a few holes...



...used my trolley jack and a screwdriver to hold the jacking point in place...



...spot weled from the top...



...seam welded from underneath...



...and a quick coat of Hammerite. wink



I then put the front of the car on ramps so I can cut the other offending jacking point off and weld the new one on. Trouble is the jacking point itself looks fine. The floor between the jacking point and the bulkhead has been bodged and the plate and filler fell out as soon as I tapped it. Grrrrr!





Here we go again. smile

Buff Mchugelarge

3,305 posts

107 months

Wednesday 4th January 2012
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Hats off to you LK smile
Top job

Liquid Knight

Original Poster:

15,665 posts

140 months

Wednesday 4th January 2012
quotequote all
Well that's it. I'm out of welding gas. I was planning to put a plate inside the passenger footwell and another outside but I only got this far...



...tidied up...




...and I'm back at work tomorrow. The car will have to wait. frown

Once again thank you for all the support, comments and constructive critique. Just set my alarm for half four as I'll be cycling. wink

moribund

3,401 posts

171 months

Wednesday 4th January 2012
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Brilliant stuff. Given the weather at the moment I hope it passes it's MOT for you!

Liquid Knight

Original Poster:

15,665 posts

140 months

Sunday 8th January 2012
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Got a bit bored at work and while I have my grinder and welder out...



...SD3 Camino?

VinceFox

20,566 posts

129 months

Sunday 8th January 2012
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Liquid Knight said:
Got a bit bored at work and while I have my grinder and welder out...



...SD3 Camino?
For cliff's sake, someone stop him.

james_tigerwoods

15,523 posts

154 months

Sunday 8th January 2012
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Liquid Knight said:
Got a bit bored at work and while I have my grinder and welder out...



...SD3 Camino?
Do it! And stick a V8 in the back...

Balmoral Green

33,554 posts

205 months

Sunday 8th January 2012
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Subaru Brat, not seen one of them for years.

Liquid Knight

Original Poster:

15,665 posts

140 months

Wednesday 11th January 2012
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Off work (job) so back to work (Rover). smile

Just a few errands to run on my bike and then I'm back to it.

Todays plan is to finish welding the inside footwell plate in place, make a bigger one for outside, spot weld it to the new plate from inside and seam weld it from the outside. Sounds fairly straight forward eh? wink

MGJohn

10,203 posts

140 months

Wednesday 11th January 2012
quotequote all
Liquid Knight said:
Off work (job) so back to work (Rover). smile

Just a few errands to run on my bike and then I'm back to it.

Todays plan is to finish welding the inside footwell plate in place, make a bigger one for outside, spot weld it to the new plate from inside and seam weld it from the outside. Sounds fairly straight forward eh? wink
Keep up the good work. Your repair and welding skills I admire.... how about some YouTube footage "How To Repair and Weld" demonstrating those underestimated skills?

Liquid Knight

Original Poster:

15,665 posts

140 months

Wednesday 11th January 2012
quotequote all
That's very kind of you to say but I'm no where near that good. My Youtube guides are for things anyone can do as well. I wouldn't want someone taking me to court because they set fire to their car trying to copy what I've done.

http://youtu.be/CVXVO-reYyQ

http://youtu.be/9-_uEg0fxc0

http://youtu.be/VCtEnk7qcZA

http://youtu.be/jF0-y3pEmpc

I'll do it next time as I've already started I would just be another photo montage.

As for today. The cycle ride to do the errands went a bit pear shaped. It's Saturday for me and I forgot the post office shuts at lunch time so I had to go an extra thirty miles into town and back. Got some bits for my Guff racer and a new frap wheel for my grinder so I can properly tidy the metal work up as well now. It was getting dark by the time I got back so I started on the seat for project Catsarse II instead. wink

Liquid Knight

Original Poster:

15,665 posts

140 months

Thursday 12th January 2012
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No more floor welding! smile

Just a slightly blowy front pipe, the 99p one from eBay has the wrong connection so I'll have to cut it off and make one. It's clean metal on to clean metal so it won't look anywhere near as ropey as the rest of the car when I do it. wink

Right today I finnished seam welding the plate inside the passenger footwell...



...made a plate to go outside and almost mirror polished it with my new frap wheel. wink



Next I drilled a load of holes in the new plate from underneath the car.





While I was drilling under the car a splinter of swaf fell over the top of my goggles and into my left eye. Rather than pillock about with eye washes and tweezers I went straight to the fridge, grabbed a magnet and wiht the help of my bathroom mirror extracted the shard from my left tear duct without irritating the rest of my eye. Top tip there if it ever happens to you. wink

Next I shaped and faced the new plate ready to spot weld into place. I needed to rotate the car ramp so I lifted the front wheel with the jack, turned the ramp and put the car back down.



I placed the new plate on a wodden block and used the jack to hold it in place...







...spot welded the plate from inside the car...



...burned the block of wood a bit...



...got back underneath the car and seam welded the new plat and an extra plate the other side of the jacking point.





Finally a quick spray with black Hammerite before putting the interior back together.

Liquid Knight

Original Poster:

15,665 posts

140 months

Thursday 12th January 2012
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If you like this thread why not start your own SD3 adventure...

http://www.ebay.co.uk/itm/1988-Rover-213-Taxed-and...

smile