FT’s Patrol Project

[terranosaurusdoug]

My welding helmet drives me insane, I was looking at welding hoods last night, with built in screen.

 

[Flying Torquewrench]

All welded back in. Not the best looking welds but good penetration so reasonable happy.

The remaining hole is normally covered by a rubber flap. Mine has torn but I have an old inner tube from a wheelbarrow tire laying around so that will be repurposed.

 

[elty001]

That looks a nice tidy job:thumb2

 

[Flying Torquewrench]

Cheers Elty.

Unfortunately the back end is in a worse shape then expected. I had hoped that it was a case of replacing the the lip on the wheel arch but O gave uncovered a lot more rust.

This is the nearside aft wheel arch.

 

[Flying Torquewrench]

Not only is the lip completely gone, the inner part of the wheel arch is also shot with reasonably sized holes in it. This will keep me busy for a few days. Fortunately the weather is good.

 

[Flying Torquewrench]

Then we have the part between the wheel arch and the bumper. In the photo below you can see the repair from 2010 which is still solid. It is just that there is no material around it anymore. This is the outside.

 

[Flying Torquewrench]

The inside of the same panel, next to the exhaust.

On the other side (offside) the panel is in similar shape.

 

[Flying Torquewrench]

On last photo for tonight. This is part of the near side wheel arch and you can clearly see the rust holes.

 

[elty001]

That's also a problem area on the terrano.
The inner and outer wheel arch panels are spot welded together then sealed.
The sealer breaks down and the crap gets in and rots them away.
I completely did away with the lip under the arch and seam welded it together with just brackets welded In place to hold the plastic wheel arch trims on.

 

[Flying Torquewrench]

On the off side I also welded brackets in and didn’t replace the lip. I made the repair panels for this side with a lip so I just keep an eye on it. On the Patrol the lip collects mud etc as it is a flat surface in the wheel arch, not the best design. Might fill it with a sealer so that no mud can collect there.

 

[Barrbeast]

On the off side I also welded brackets in and didn’t replace the lip. I made the repair panels for this side with a lip so I just keep an eye on it. On the Patrol the lip collects mud etc as it is a flat surface in the wheel arch, not the best design. Might fill it with a sealer so that no mud can collect there.

Shared by the Y60s and was the same on my old shoguns

I take a boot brush and hand to the inner lip every time I come back from offroading to get rid of the build up asap.

 

[Banshee]

All welded back in. Not the best looking welds but good penetration so reasonable happy.

The remaining hole is normally covered by a rubber flap. Mine has torn but I have an old inner tube from a wheelbarrow tire laying around so that will be repurposed.

Very Very impressed, super work mate :thumb2

 

[Wallace]

Coming along nicely. :thumb2

 

[Flying Torquewrench]

It appears that this is only the start. Most of the back end is rotting away.

Removed a part of he bodywork behind the rear wheel to be greeted by a lot more rot. Initially I had planned on replacing the rotten metal but now might cut this off completely and replace it all. It is all hidden behind the bumper so the shape is not that important.

 

[Flying Torquewrench]

The wheel arches are rotten as the photo I posted yesterday shows. Replacing it bit by bit.

The bit on the right is the lower lip in the wheel arch. The middle bit connect to the upper part of the wheel arch. Finally, the left bit is welded onto the bodywork. Making pieces like this simplifies the welding done on the car.

 

[Blocky10]

The wheel arches are rotten as the photo I posted yesterday shows. Replacing it bit by bit.

The bit on the right is the lower lip in the wheel arch. The middle bit connect to the upper part of the wheel arch. Finally, the left bit is welded onto the bodywork. Making pieces like this simplifies the welding done on the car.

You're making this look easy. I'd hang this part on the wall:lol:lol

 

[Flying Torquewrench]

I have a question for the more knowledgeable people among us.

What sort of repairs can you make to the chassis so that it passes the MOT?

In 2018 it failed the MOT because of rust on the chassis near the tow bar. The garage repaired this by welding an angle iron on the inside/underside. The car subsequently passed the MOT. I have now noticed a bit of corrosion near the tow bar on the other side. When I bought my sheet metal I also orderen two sets of 2mm and 3mm steel sheets.

My plan is to cut a section of 3mm and fold it around the chassis beam (like the angle iron). Unfortunately without taking the body off there is just no space to cut the rust out.

In addition I have some 6mm and 8mm flat steel which I plan to weld to the underside of the chassis rail. My intention is to drill holes through this so that the tow bar mounts through this. This will redistribute any forces from the tow bar mounting area further up the chassis rail.

Any obvious flaws in this plan?

 

[Banshee]

Amazing work in here!!!

Very impressed at the fabrication skills within this forum between some members.

I need to get my learning cap on :bow

 

[Flying Torquewrench]

Banshee, thanks for the compliment but it looks more complicated then it really is.

The panel above is just two arches bent separately with the shrinker/stretcher and then welded together. Any panel job can be broken down on pieces and each piece made separately.

Patience is what is required to get a panel right. The wing panel took me 4 days to do and the whole back end of the Patrol probably 2 to 3 weeks. That means working daily on it for about 5 hours.

 

[Flying Torquewrench]

Every panel hides more rust. I had hoped to only spend a week or three on it but that is not going to happen.