Morris Minor Owners Club

First job is to cut off some of that rot to get access to the inner panel. I suspect this is one of the most neglected repairs on the Minor as access is very difficult without removing quite large sections. It is also one of the most highly stressed areas of the bodyshell though, providing direct support for the spring hanger.[frame][/frame]

Before cutting away the rot I made a card template of the panel for reference...[frame][/frame]

The panel was then cut back to good metal...[frame][/frame]

I then used my template and rubbed through to find the cut edge...[frame][/frame]

Then I made an accurate template for the repair panel...[frame][/frame]

Which was cut out with the jigsaw and bent in the vice...[frame][/frame]

And welded in...[frame][/frame]

Now there is a continuous panel once more running the length of the car...[frame][/frame]

The upper side of the "box" is still sound and now the boxing plate extension is cut back to good metal...[frame][/frame]

Again using a card template the repair panel is cut to shape...[frame][/frame]

Checked...[frame][/frame]

Welded in...[frame][/frame]

And dressed off...[frame][/frame]

That's three sides done! The lower side is made up by the outer floor panel that can be fitted once I have dealt with that hole above where the spring hanger was...[frame][/frame]

That's amazing! And you make it look so simple - excellent discription, thanks.

Taupe would be proud.

Compliments indeed! Thanks guys.

Now to fill that hole...[frame][/frame]

Pretty much a flat plate and the usual card template etc.[frame][/frame]

Now I can fit the outer floor lower repair section. It's really useful to have the spit for plug welding this part, as I need to do from three directions...[frame][/frame]

All dressed of and it creates the bottom side of the "box". Now to continue rearward...[frame][/frame]