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Juular's ovlov rescue centre - poking holes in a 240 (now fixing some)


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Brilliant progress, especially given your outdoor circumstances and sub zero temperatures!! 

That door pillar looks brilliant, and the fact the swages line up,  and there’s zero sag from that bank vault of a door - even before the pillar is complete - deserves a medal on its own.

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  • 3 weeks later...

It's going to be a common theme that I wish I'd got more done but the weather (and other things) have got in the way. Nevertheless here's an update.

It was cold.

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Can't remember the last time I saw the canal frozen over.

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Temperatures here were in the region of -5 most days I had free. As much as I said I don't mind the cold, when the tarp is stuck solid to the car I make an exception.

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Still got a few bits and bobs done over the holidays. I long wanted to make a start on the inner sill bit that's gone, but connected to that is the chassis outrigger which is buggered on the nearside.

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First the tranny mount has to come off. It's foosty but solid.

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The thick underseal is impervious to most methods of removal and even a blowtorch and scraper only got some of it off. So it's out with the big gun.

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Finished that off with the small wire wheel on the drill, then a coat of hydrate 80.

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Then epoxy mastic.

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I'll probably leave it grey.

Now time to butcher some Volvo.

Here is the rotten floor with outrigger underneath.

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Cleaning back to find spotwelds.

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I decided to make my life easy and buy a set of these mini holesaw spotweld removers.

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They are really good. Some quick zaps with the drill and the panels are separated.

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A quick chap with a chisel..

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And off it comes.

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This is the replacement panel. They are £50 a side so I will be making it/them myself.

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Thankfully a pre lockdown steel delivery arrived.

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Scratched out the shape.

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Snip.

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Into the metal basher.

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Fits ok. The gap at the front is the missing floor 

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Tidied it up, then Made up some bits for the floor, inner and outer sill.

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Cleaned and prepped.

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This is where things went wrong. I decided to try painting these parts in zinga to protect the internal faces after welding. But no matter what i couldn't get it to stick. It just scratches and flakes off with no effort. I think I will have to abandon that plan.

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So currently I will be returning to Screwfix zinc galv spray which is cheap, weldable, sticks well and seems to be doing a very good job so far.

Floor on its way in.

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Floor and inner sill welded in.

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As you can see this job is 99% faffing around with metal, 1% actual welding. 

Too cold to finish off the welding at the moment, will update when I can feel my toes!

 

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