jims-terrano Project

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You do have to wonder Rick, just how many peoples trucks will be like this and not picked up yet. Normally only an MOT would pick it up, lets face it even the tester of this truck didn't pick it up.

I have never checked mine in the 20 years I have owned her, I am dreading removing the front bumper to find that :eek:
The bits you can see on my Mav, look fine except for the bumper support out riggers, now they do need some work...:augie
I waxoyled what I could get to, it passes MOTs... so I ignore it...:augie


If I recall, the whole front panel, not bumper support, can be purchased at a price.
 
You do have to wonder Rick, just how many peoples trucks will be like this and not picked up yet. Normally only an MOT would pick it up, lets face it even the tester of this truck didn't pick it up.

My current work motor is worse than yours, I strapped some metal on it to get MOT telling myself when I change the wings (held together with fabric tape) that I will have the whole front off and sort it like you are doing, but so far just not had the time, glad in a way cos now I will adopt your tube idea, brilliant, Rick
 
Think the front bumper off my other truck will be coming off for detailed measurements and photos. Anyone good at drawing plans?
 
Looking good Jim will be well worth it when done Good luck. Kev
 
Cheers Kev and keep checking in, trying to get some time off work next week to get some more done.
 
A Little Progress

Got a couple of days off work so took the chance to get a little reconstructive work done.
The day began by separating the front bumper plastic cover with the metal reinforcement, not too bad but two of the wheel arch screws simply wouldn't budge so had to take the angle grinder to them.

Note to self, must remember to wear long sleeves when welding. Nice bit of sunburn on my arms:doh

I'm guessing that my welding skills are not up to some of our experienced members here but I have to say it has got better as I did more but the most important thing for me is not just is the bumper solid but I had a dam good time and really enjoyed the afternoon playing.

First of all, meet Miggy my new friend.


Now this is a before shot but sadly the other side as I just cracked on without taking a photo of before but you get the picture, it was a bit rotten.


Used several strips of metal to repair the inner piece of the bumper end, laid side by side and sometimes over lapping. I took the grinder to the welds to check there were no holes and the weld had actually taken on both sides.




This is the bigger panel that I made in one section, notice how I cut slots to enable the panels to fit around edges. The original was sunk into the reinforce but far easier to have it this way, cut the original section away to get rid of the rust.





By the time I had got to this stage I was tired and wife was home so time to pack away before I could grind the welds down, still some welding to do there. Will see about time tomorrow and may be repair the other side. The rest of the bumper is just surface rust so will take the wire brush attachment on the grinder to it and then treat it all with rust remedy, can't remember the name of it but Paraclar amongst others recommended the brand so bought some. Will then give it all a good coat of Hammerite before putting the plastic cover back on.

One job at a time!!
 
Looks good so far jim:thumb2

You'll learn with welding as you go, practice is the best way :thumb2:thumb2

Mine still vary:augie
 
Good stuff Jim, practise makes perfect, they'll get better as you go.......:thumb2
 
Front Cross Member

OK here goes for an update, it feels like I'm actually making progress at last. So here's the front cross member, it didn't fail it's MOT but I knew it would be rusty and when I removed the front bumper all was revealed.
So you'll see the old cross member being removed and new one being constructed using 80mm x 40mm Box Section and 3mm plate. I've seen several replaced but not often the body mounting behind which in this case was rotten more so on the passenger side. Think the body mount rots out worse because there are 3 layers of steel and the inner seems to rot and swell forcing the other skins apart, you'll see what I mean. So cleaned these down and rebuilt where rotted and the rest was cleaned down with wire brush on the angle grinder and then treated with Fertan and later 2 coats of Hammerite.

Had started cleaning up the old cross member before deciding to remove rather than fix.




Looking much cleaner




Rust has turned black due to a coat of Fertan






Test Fit!!!


Radiator Mountings made from 1.6mm plate with folded supports to stop the bracket flexing.


Finally fitted, just need to drill and bolt the bottom of the centre support.


I'm now on with the inner wing at the passenger side so the next update will be that.
 
Passenger Side Inner Wing (LH)

Well here's pretty much as far as I've got with the inner wing, a bit more welding done but no photo's yet and I've run out of gas:doh

you can see some previous welding and also where the metal is now so thin it has cracked around the plastic guard bracket.


Same area all cleaned up


Remember this?


Well this happened to it :lol at this point I wasn't too sure if it is really a repairable car but it's actually getting solid now we are getting new metal there. Had to remove the air filter brackets along with the fuel filter, abs pump and their brackets to clear the inner wing.




Most importantly safety first!!! well built axle stands and also stuck the wheel below to be safe.


More to follow but not for a few days now. Have to say I'm loving this and it's building both my confidence and also my son's too.
 
Nice job Jim, I feel ashamed I just bash it with a hammer and put some paint on it. maybeez I had too many years trying to do a good job instead of driving what I got...:thumb2
 
Nice job Jim, I feel ashamed I just bash it with a hammer and put some paint on it. maybeez I had too many years trying to do a good job instead of driving what I got...:thumb2

I've got the luxury that it's not a daily ride so I just do a bit and leave it.

I'm having great fun and enjoying spending quality time with my son, worth more than anything is that.

Today I nipped out and pulled the front brakes apart, not had the confidence to do that for years.
 
I've got the luxury that it's not a daily ride so I just do a bit and leave it.

I'm having great fun and enjoying spending quality time with my son, worth more than anything is that.

Today I nipped out and pulled the front brakes apart, not had the confidence to do that for years.

Time you will never get back :thumb2

Make the most of it while you can, I had a 12mile cycle ride and a mile swim in the sea today.. the things you do hey....

#large glass of red...:thumb2
 
It's awesome to see people take the time and have the passion, scope and enthusiasm to keep their trucks on the road :clap... Good work..A lot of vehicles get scraped for minor stuff and people move on to something newer but not new and it ends up costing a fortune for silly stuff.
New vehicles are just so expensive to fix once out of warranty especially newer diesels...I like older stuff with less complicated everything.. My plan next year is to buy the newest lowest mileage GU patrol I can afford poss 05-07 get it rust treated and just keep it...well that's the plan.
 
Another nice read up :thumb2

Cracking work with the welding buddy, as already said, it's got to be so refreshing to know that you can take as much time as you need as it's not your daily driver :thumb2

Keep it up
 

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