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Tickman's stuff. Exhausting day.

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7 hours ago, Tickman said:

Back on with the cleaning of the underside of the car.


Happily they did exactly what I wanted, so snidy Brillo pads for the win.

Who'd have thought Asda would be for the win!


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I've got to the point everything behind the crossmember is cleaned off so I made it blueish.


Then I rolled it back a bit to start the fixing of stuff.


Repair panels were ordered and delivered.


Time to decide what's first. This bit of the rear arch looks complicated enough to repair.


Quite awkward to get in with the grinder.


End of play today.


Will see how I get on next time.

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Started plugging some of the holes. Started by getting this out and putting a 90 bend in some steel.


Then some card was used.


Roughly the right size.


Then make the slight curve.


Check for fit.



Yep, that will do. Apply some weld through primer.


Get welding and a bit of a dress back.


Next bit.


Piece for it.


Check for fit.


Stick it in.


Dress it back and a bit of paint to cover.


Then move further around the arch and remove the next issue.


Needs a bit more cleaning up before making stuff to go back in.

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I've been chipping away at this over the last few days but I kept almost tripping over stuff as I was trying to get on with it.

First I decided the angle grinders needed out of the way so I put this on the end of the bench on wheels.


Loving the new welder.


Something like that will do.


But the cables are an issue, I know...


That works, next the welding trolley developed a wonky wheel, I needed a spacer between the wheel and retaining split pin so I had a look around and found part of a fallen soldier.


Then the bumper, exhaust and other bits were in the way so I dug out some steel and got to work. I also moved the lathe over and created a bit more usable space.


Time to get on with the car. Previously I'd left it here.


Knowing that this was going to be happening I've been gathering cereal boxes.

Making the piece required using three bits. Card deployed and some really handy little clips to hold them in place.


I need to sort out the flange on the end of one of the the sill panels.


Piece cut and welded.


After a bit of rough shaping I welded the two big bits together and tried it in place.


Then the flange was added, this was a 10mm strip that I used the shrinker on to get the profile required. Then they were welded together and dressed back.


A few more holes were required so they were drilled out ready to weld



Welded in.


I dressed this back.


And a quick bit of paint was added.


I'm really happy with the way that has gone today.

Some more will happen possibly over the weekend but more likely next week.

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Just now, Split_Pin said:

Excellent progress, I love proper fabrication like this both on the car and on sensible workshop organisers.

Oh and your cardboard templates are GRRREAT!

He used flippin' cornflakes, man! Not even Frosties. :P

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Fine work there. I find the boxes of Kelloggs products make excellent templates. Its just eating the contents beforehand thats the tricky bit. Luckily Mrs_Nuts helps me out with that stage and I can just stick to toast and that.

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Bit more today. I cut some steel ready.


Put a bit of a bend in them.


Started sticking them together.


Bit more


Dress it back.


Chop out some stuff to make space for it.


Put some holes in it.


Stick it in.


Move along a bit and start again.


Make the next bit.


Dressed back.


Try it in.


Not welded in yet but some more cut ready for next time.


That's all for now.


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4 hours ago, 320touring said:

That looks ace chap. Panels look very clean with no distortion.

This x100.

In the past I've lost patience while welding and just rattled a patch straight in then suffered the consequences and had to deal with a panel that resembles corrugated iron and doors that don't shut properly! This is very nice work indeed.

Still can't get over the condition of the car though. This would have been considered a completely rot free and mint example 40 years ago never mind surviving like that into 2020.

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That's it ready to put in.


Then it was a bit of repeat.


Which brought me down to here.


And the other side of the arch was at this point.


I hoped to get this finished off today so end of sill area first.

Cleared away all the stuff that was weak.


Treated the inside.


Used some card to give me an idea of the piece needed which was something like this.


Quick bit of paint.


In the hole ready for welding.


Then welded, dressed back and a bit of paint.



Now just* the rear of the arch.


More panels made.


Bits at the back were a bit knackered.


Flange replaced.


Then the squared hole to the right needed a bit, I also replaced the flange at the bottom and the rest of the arch apart from the bit around the bumper mount.


That bit was done and dressed back.


Then the last hole needed sorted. This.


In and done.


So that should be the rear arch done apart from the wing mounting nuts / holes.

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I've been doing other stuff for a few days, when taking the bin out yesterday I noticed the exhaust on the Toledo wasn't sitting where I normally does. A quick look underneath showed some fuckedness.

I had a look online for replacement parts and the only system available if a stainless system through the club for £315. That will not be happening.

I took it to the workshop and up it went. I pulled off the tailpipe that was loose.


It took quite a bit of effort to remove that. This is the bit underneath that is left.


I checked the whole system and it is just the last corner and tailpipe that is knackered so some bits were ordered last night. Exhaust parts are surprisingly difficult to find on the internet and I couldn't find any others apart from Jetex that @dome had recommended. So some Jetex bits from Demon Tweaks at on their way soon.

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