The rust in this Torana's floor appears to be minor- but is in fact pretty bad- the whole pan is thing with decay. I have overlaid the new Rares Pan and gone around the edge with some pressure pack spray so we know what area to cut within. Remove any wi
Date: 27/05/05
The rust in this Torana's floor appears to be minor- but is in fact pretty bad- the whole pan is thing with decay. I have overlaid the new Rares Pan and gone around the edge with some pressure pack spray so we know what area to cut within. Remove any wires that may be in the way as well as carpets and other flammables. make sure the car glass if still fitted is protected from spatter and sparks.
It is easier to fit a whole pan instead of just a small portion. In this case there was reasonable amount of excess not required so we trimmed the new pan down to size first. The important thing to remember is not to cut yourself short! Make sure
Date: 27/05/05
It is easier to fit a whole pan instead of just a small portion. In this case there was reasonable amount of excess not required so we trimmed the new pan down to size first. The important thing to remember is not to cut yourself short! Make sure the new pan once cut will cover the affected rusted area and beyond. You cannot weld to rust!
After I have wire brushed away all the crud, I lay down the new abbreviated pan and mark once again the area it covers with some pressure pack spray.
Date: 27/05/05
After I have wire brushed away all the crud, I lay down the new abbreviated pan and mark once again the area it covers with some pressure pack spray.
Working within 12 mm of the spray line I trim around the perimeter with a 1mm cutoff wheel on a 4" grinder. These wheels are fantastic for clean accurate and distortion free cutting. Make very certain that you are not cutting cables or lines und
Date: 27/05/05
Working within 12 mm of the spray line I trim around the perimeter with a 1mm cutoff wheel on a 4" grinder. These wheels are fantastic for clean accurate and distortion free cutting. Make very certain that you are not cutting cables or lines underneath before you start. Check to make sure you are not aiming those sparks at the glass or anything else flammable - You can never be too vigilant in this area of concern.
The cuts are made within half an inch of the spray mark. Daylight is a good thing - this will show you where the floor braces that you don't want to cut through are- so go lighter in those areas. Also if you have not been very diligent in your scan
Date: 27/05/05
The cuts are made within half an inch of the spray mark. Daylight is a good thing - this will show you where the floor braces that you don't want to cut through are- so go lighter in those areas. Also if you have not been very diligent in your scan of the underneath for cables and fuel lines - about now is the time to utter the word bugger. Nothing dramatic to report here.
Trim away as much bulk as can. The next step is to drill out the spot welds if you can find em'! This is where the air chisel comes out and helps to locate the fixed points and separate the pan from the brace. Go easy here as you don't want to dama
Date: 27/05/05
Trim away as much bulk as can. The next step is to drill out the spot welds if you can find em'! This is where the air chisel comes out and helps to locate the fixed points and separate the pan from the brace. Go easy here as you don't want to damage the floor brace. If the welds wont break with a chisel then hammer the pan flat again around the weld and using the grinder you should be able to make them thin enough to break the weld but not grind through the brace. Patience is the key here.
This is what the cleaned up brace free of pan should look like. The brace should then be coated with an etch primer or some other type of nonflammable weld through primer. Any nicks with the cut off wheel should also be welded as shown here befor
Date: 27/05/05
This is what the cleaned up brace free of pan should look like. The brace should then be coated with an etch primer or some other type of nonflammable weld through primer. Any nicks with the cut off wheel should also be welded as shown here before fitting the new pan.
The new pan is oxy hammer welded into place after it has first been plug welded to the underlying floor braces. Excess overlap is trimmed away as the oxy welding progress. The finished pan should require little or no finish grinding. Th whole pan i
Date: 27/05/05
The new pan is oxy hammer welded into place after it has first been plug welded to the underlying floor braces. Excess overlap is trimmed away as the oxy welding progress. The finished pan should require little or no finish grinding. The whole pan is primed with etch again and then sealed around every weld with brush able seam sealer or tar as shown here...on BOTH SIDES!
(Rust repairs to Kim's FC floor)
So what is oxy hammer welding? Why did I leave a half inch overlap? Oxy hammer welding involves butt welding two panels together. The overlap is left for a reason - as the welding progress around the pan, the pan shrinks. Overlap is trimmed away just
Date: 06/08/04
So what is oxy hammer welding? Why did I leave a half inch overlap? This is a different car but the principal remains the same. Oxy hammer welding involves butt welding two panels together without overlap. Confused?. The overlap acts as a guide and supports the new pan - as the welding progress around the pan, the pan shrinks. The overlap is trimmed away just ahead of the oxyhammer welding using the 1mmm thick cut off wheel. A perfect gap is left for filling with welding wire. As an inch is welded- I call dolly and my assistant underneath the car places the dolly against the new hot weld and I hammer forge the two panels flat and even. This makes for a far neater job that can be controlled easily.
