Morris Minor Owners Club

Hi, After removing my rear wings to repaint, it seems like the previous owner had used plastic body filler on the inner wing flange, it seems to be about 2-3mm in thickness, and horribly flaky. I've removed most of it and found a few rust holes.

What should I do when refitting the wings, refill it using P38 or Plastic metal, or use something else?

Also, one of the fixing bolts near the rear door turned in the captive nut and I was unable to reach the other side, in the end I used the angle grinder to cut it off, what's the best course of action now? bearing in mind I don't yet weld (better start learning!)

Is there anything I can do rather than cutting through and welding a new captive nut?

It needs welding! Nothing else is satisfactory.

bmcecosse wrote:It needs welding! Nothing else is satisfactory.

I agree with BMC, the last owner did a poor bodge, now its time to repair properly. Cut out all the rusty metal and make up sections to fit neatly. Butt weld these in and grind the weld smooth on the wing side. Offer up the wing to mARK THE position of the bolt holes, drill large enough holes for the bolts and weld in 5/16BSF nuts to the inside of the flange (dont need to be fully welded around the nut, just a few really good big penetrating tack welds), then paint and waxoyl where the mounting flange meets the wing.

Or, if the mounting piece is really rotten, you can buy repair panels from the usual Minor parts suppliers. These come with holes allready but also need to be butt welded in and nuts welded to the inside.

so there should be no filler in there at all besides the piping?

None, as filler will absorb moisture and cause even more rust.

Here's some images...

The thing is there is a lot of good metal still there when I grind off the filler, does it really need new metal across the whole flange? Its just rough and pitted.

Yes - new metal to put it right. You've gone to all the trouble to take the wings off - may as well sort it now while you have access!

Thanks for the info.

I've just laid my hands on a Mig welder, so I'll start learning.

Should the fuel tank come out before I start?

Up to you - or you could flush it out and then fill it with water before you start.

Its not that difficult to remove the tank on a minor. Just the filler hose, sender wire and fuel pipe (whitworth open ended spanner!). Drain the fuel first from the drain plug at the bottom. Then undo a load of self tappers around the fuel tank flange and the tank will lift out inside the boot. (remove wooden boot floor first!)

my issue is that a - I expect everything to break off when i try to undo it, the boot floor screws are already rounded off, and also the tank is currently full, what do I do with all that fuel?

Put the wings back on (with waxoyl on the flange to slow further rusting), and use the car till you've run the tank down to a gallon or so then drain into a suitable container (funnel into fuel can(s) ).

In the meantime, buy Mig, grinder, wire brushes etc learn to weld, then plan on having minimal fuel in tank when you are ready to remove.

A good place for Mig welding tips :- http://www.mig-welding.co.uk/

Get lots of 1mm off cuts and start practiseing.

Boot floor screws can be slotted with a dremel then undone. Plud-gas will make the other fixings easier to undo.

Do you have another petrol vehicle? If so, pump the fuel out a can at a time and transfer it to the other car. Keep the last can to put back into the Minor after doing the job so you will have some fuel to drive to the petrol station.