240 GLT saloon restoration project

[Othen]

Originally Posted by Juular

Progress update..

Fabricated another outrigger for the offside.

Started smoothing out the passenger A pillar.

Filler

Getting there

Thought I'd tackle this as it's been giving me horrible feelings in the pit of my stomach



I Made up some rust eater from citric acid and corn starch.

Left overnight, it eats the rust out of the pits.

Smoothing out

And ready for a new windscreen. Does anyone know a good fitter in central Scotland?

You’re a better man than I am, Gunga Din!

... well, you are much braver when it comes to cars. You have done a remarkable job on that car and should be proud of yourself. Well done indeed, I'm looking forward to seeing the car finished, do you think it will be done this year?

[Laird Scooby]

Originally Posted by Othen

You’re a better man than I am, Gunga Din!

... well, you are much braver when it comes to cars. You have done a remarkable job on that car and should be proud of yourself. Well done indeed, I'm looking forward to seeing the car finished, do you think it will be done this year?

I was about to say the very same words! That Gunga Din got about a bit!

Certainly a very brave move welding round the screen/A-pillar although with the amount of practice the OP has had on this car alone, probably just "another day at the office" for him.

Still excellent work though!

[Bob Meadows]

Hi:~
Regarding your windscreen- just used Auto Windscreens on a 1988 240, straight forward and they managed to get me a screen with a top colour band.
This one is now bonded in with Polyurethane (one removed was a mastic)
The outer chrome trim is clipped in pace and I had been keen to retain the feature- these trims are renowned for not fitting properly in corners as the outer rubber gasket shrinks back over the years.

I modified my seal and will shortly do a how too on it should any others want a real messy time with Polyurethane! but it works.

It is worth reviewing all previous mail and posted details regarding the screens and options that can be used to use a larger plain rubber seal type from later cars- otherwise very good service from the screen company.
Regards Bob.

[Othen]

Originally Posted by Bob Meadows

Hi:~
Regarding your windscreen- just used Auto Windscreens on a 1988 240, straight forward and they managed to get me a screen with a top colour band.
This one is now bonded in with Polyurethane (one removed was a mastic)
The outer chrome trim is clipped in pace and I had been keen to retain the feature- these trims are renowned for not fitting properly in corners as the outer rubber gasket shrinks back over the years.

I modified my seal and will shortly do a how too on it should any others want a real messy time with Polyurethane! but it works.

It is worth reviewing all previous mail and posted details regarding the screens and options that can be used to use a larger plain rubber seal type from later cars- otherwise very good service from the screen company.
Regards Bob.

It would be interesting to read that piece about modifying the fitting for the chrome type seal Bob (the RB has the later type, wide seal).

Alan

[Bob Meadows]

Should be able to post it this week Alan- pictures ready- just in the middle of oil changes for the car & the Riley.
Regards Bob

[Juular]

Originally Posted by Laird Scooby

Certainly a very brave move welding round the screen/A-pillar although with the amount of practice the OP has had on this car alone, probably just "another day at the office" for him.

You have done a remarkable job on that car and should be proud of yourself. Well done indeed, I'm looking forward to seeing the car finished, do you think it will be done this year?

I bought this car partly to learn how to weld. This time last year I didn't know how to turn the welder on! So I really appreciate all the feedback.

I'm hoping I'm able to get an MOT for the car in the summer. Then I'll have to consider painting it, which is another thing I have very little knowledge of. What can go wrong?

[Juular]

I'm still a bit behind in updating the photos as I've done a bit of work over the past few weeks.

The bulkhead was in a bit of a state.



The twisted wheel on the grinder is a good way to find sound metal as it tears away all the rusty bits and punches holes through the pits.





Started cutting away the rust and found a nice surprise waiting.





All cut out, cleaned and treated.



Repair sections primed and drying.



All done!



This looks nice..





A lot of templating was done using duct tape.



And built up in small sections.







Once happy with the shape I drilled the hole for the washer and cut the slot.



Final adjustments.



Final seam welding together.





Welded in place then washer back on.





The grille hides it.



Bit of paint and done.

[Juular]

The front brake harware is pretty dead.



I created new brackets and things from 2mm steel.





Created new flares and unions where the hoses had to be cut off.





Installed new inner tie rods.



Mounted on crossmember.



I'm still waiting on some parts for the front so I moved my attention to the back.

Pulled the rear axle.





The shock mounts are fine... which is a shock!



Back end is largely OK apart from the inner wheel arches.





The chassis rail has a hole.



Cut out 1.



Repair 1.

New captive nut for fuel tank bolt.





Cut out 2 (I hoped to avoid this bit, but reality dawned).



Repair 2.



Second layer.





And the chassis is pretty much done.. no more holes in the rails.



Started cutting off the arch flanges.



Pulled off some of the plastic lower trim. Ouch.





Roughly shaped up using pliers and bashing the metal with the palm of my hand into place. It's going to be hidden so doesn't need to be smooth or beautiful.





That's me pretty much up to date!

[Juular]

Originally Posted by Bob Meadows

Hi:~
Regarding your windscreen- just used Auto Windscreens on a 1988 240, straight forward and they managed to get me a screen with a top colour band.

Thanks! I will give them a call. I'm hoping to get one with a blue band as well, although I'm not fussy about the outer trim. The one on this car was already the large black surround. It will hide some of the places I have welded!

Would you be willing to share how much it cost you, just so I have a rough figure to budget for?

[Othen]

Originally Posted by Juular

I bought this car partly to learn how to weld. This time last year I didn't know how to turn the welder on! So I really appreciate all the feedback.

I'm hoping I'm able to get an MOT for the car in the summer. Then I'll have to consider painting it, which is another thing I have very little knowledge of. What can go wrong?

Well, you have certainly achieved that aim my friend, your MIG welding is very good indeed (as is your metal fabrication). I think you mentioned previously that your dad had been a professional welder, I'm guessing he gave you some help to get started, but what you have achieved is quite remarkable.

Well done, if you could get it through the MoT test (maybe painted in primer) this summer that would be a marvellous achievement.

Do keep up the reporting - we are all enjoying this thread a great deal.

Alan