Traveller Restoration

[Neil MG]

Neil -I don't normally follow resto threads - but yours is truly amazing! My head spins at the work you are doing. On the crossmember - do you think the heavy 'spot' welds through the floor are sufficient? Or do you intend to do any stitch welding to the floor?

Cheers, much appreciated.

I have pretty much replicated the factory, using the existing drilled welds on the tunnel an a similar pattern along the floors. I also put the four stitch welds underneath as original. There is also a bit of extra welding on both outer ends too, so it is rock solid!

[Neil MG]

Now onto the driver's door and the original was in a pretty horrible state. I got a reasonable replacement, but it needed the usual repairs at the bottom. Here i have already removed the rotten metal...[frame][/frame]

[Neil MG]

First the bottom was prepared for the new section...[frame][/frame]

[Neil MG]

The seal retaining channel was plug welded from the top to avoid damage...[frame][/frame]

[Neil MG]

And the panel welded on...[frame][/frame]

[Neil MG]

I always like to keep as much of the original metal as possible (might not always look like that!) and cut the repair panel instead. So I only used the lower edge and by sliding inside the door was able to mark where to cut...[frame][/frame]

[Neil MG]

A bit of preparation to help prevent it rusting so quickly (50 years!?) next time...[frame][/frame]

[Neil MG]

The section was first tacked into place, being careful to maintain an exact gap and flush...[frame][/frame]

[Neil MG]

Lots of patience required here, making sure the panel didn't get too hot and there were no pinholes in the welds...[frame][/frame]

[Neil MG]

The flange was then tapped over and secured to the door. After dressing off the welds, the door was fitted along with the rest of the panels to check for gaps and flushes...[frame][/frame]

[Neil MG]

The door was fitted first and aligned at the rear, If necessary shims or a BFH can be used, but I had already set the hinge panel when I was doing the welding. The wing was then fitted and aligned with the door, adjusting the inboard/outboard position of the door to get a flush fit (front and rear!). The inner flange was checked and adjusted where necessary (smaller hammer and dolly) to give an even gap all round the door for the seal...[frame][/frame]

[Neil MG]

This was done for both sides before the front closing panel, front panel and bonnet were fitted. Everything seems nice and level, but there is some fine tweaking to be done...[frame][/frame]

[Neil MG]

I managed to get a pretty good replacement passenger door...[frame][/frame]

[Neil MG]

And again the setting I did when welding the hinge pillar has held up...[frame][/frame]

[Neil MG]

Another area that seems to be a potential problem is the glass surround and so that was checked for clearance too...[frame][/frame]

[Neil MG]

Just realised that I have missed a post here. Before fitting the panels I removed all the bitumen coating from the original floorpan and took the car off the spit...[frame][/frame]

[rogerowen]

Totally Gob-Smacked! You are obviously a man on a mission! This is so inspiring. Thank you so much for keeping us all posted!

[TvdWerf]

where did you bought the time machine?
My boss does not accept that I should use so much time for my MM ;)

[Neil MG]

Finished welding the front end and was at least able to use the original bumper brackets and wiper mount![frame][/frame]

[bmcecosse]

Thanks Neil - any chance of a few more pictures of how the Xmember was welded on ??