Ray, the crossmember ends are 50cm not 50mm. The 50cm goes up to and covers the end of the chassis legs. I agree, 50mm is pretty useless and I would check the ends first with a hammer and screwdriver to see if they NEED replacing first!
Lux_Moggy wrote:Hello,
Inspecting the car this afternoon, I think that I need the following panels.
1 x Door Hinge Pillar-Complete R/H
1 x Floor Edge Panel (Inner Front) R/H
1 x Outer Undersill R/H (2-Door/Convertible)
1 x Cross Member End (50cm) (Less Jacking Point)
1 x Jacking Point (For RP103/104)
Any others that I should think about ordering?
Difficult to say without cutting back the metal and seeing if more rot appears. But from the photos you should be OK.
From what Chris said. I should do these panels one at a time. What order would you suggect that I do them in.
As you cut the old ones out, you'll find they usually have to go back in a certain order to make life easier. For example, for me, the sill then the crossmember end then the jacking point. Also, the floow edge panel has to be secured at it's outer edge to the boxing panel. In my last case, you could not get to this with the outer sill on, so that had to come first. Of course to line things up and make sure they fit, I trial fit them using clamps, grips etc and when I'm happy with the fit, I mark the areas, remove them all then start tacking and welding on (checking periodically that it all still fits together OK as when you have welded panels in due to heat distortion and knocking edges flat they can move slightly or be in a slightly different position from the 'unwelded' position). This does not usually cause a problem but I prefer to check as I'm going along.
Also what is the best way to clean off old wax oil and dirt?
Old wood chisel, screwdriver and wire brush in an angle grinder. I also mark the areas to be welded and only remove about an inch to 1.5 inches around the welded area back to bare metal. Make sure you remove it ALL in those areas though otherwise it will spit and you'll not get a good weld. Don't just attack it with the wire brush attachment though as you'll just move the underseal around. It needs the majority scraping off first. Also, at the weld edge I like to 'rough' it up using a grinding disc which really removes everything and prepares it for welding better.
How do I cut out the old panel, and what perperation is needed be I start welding. I have never done any body work before. Am I getting myself into deep.
Well, that depends on the panel, but mostly I use a combination of cutting disc, grinding disc, mole grips, chisel, large and medium screwdrivers as in some areas you just can't get an angle grinder in. Especially 90 degree corners (floors for example). In these cases I cut (with the cutting disc) as far as I can go and then chisel the remaining inch or so with a steel chisel (small type).
If you are doing it in pleasant surroundings and the temperature is OK and you have plenty of light then it's possible you might enjoy it! But on your back in the wet is NO fun. As for your ability to do the job? well, time will tell, but everybody does it for the first time once and if you use common sense and stop to think every now and again you should be OK.
I will say one thing that's very useful to have in mind though: Measure twice and cut once! It's an old saying but VERY useful!
Websites: 
powers of 3 and all that! Odd isn't it that on ESM's site it's in cm not mm. 
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