Restoration Thread - Red 1990

[NeilJM]

Thanks for the help and advice in other threads over the last few years. The last conversation was just an introduction thread so I'll get something going in here. I'm about to get much more needy!

I'm finally having to tackle the big job - welding for rust repairs. I'm going to use this thread partly to document, partly to ask for advice and partly just to think out loud as I go. I will post pictures step by step as I get to each area - hopefully it will help anyone else tackling similar things.



The main job: All 4 corner sills, plus either patch or entirely replace the "chassis rails" (or whatever they actually are) that run along the floor.

While I have each corner up in the air and dismantled: Clean up and refurbish suspension, send coilovers off for refurb, regrease polybushes etc.



I have done a welding course and will practice a bunch more before tackling the car.



Next step before I can start fixing is to get kitted out. Lumphammer kindly shared a list a little while back, which I'm using as a basis. A few bits to confirm:

1. I have a welding machine: https://www.weldingsuppliesdirect.co.uk ... elder.html - I have a full bottle of Argon/CO2 mix and some 0.8mm wire. I presume I will need to change for 0.6mm wire. What other parts do I need to get for this? Tips, and maybe a fresh shroud?

2. Grinder https://www.screwfix.com/p/dewalt-dwe42 ... 240v/2689j

3. Spot weld drills https://www.dwtoolshop.com/presto-8-00m ... 6cQAvD_BwE

4. Clamps - what sort do I need, and how many? https://www.powertoolsdirect.com/milwau ... 0mm-11in-1 ? https://www.toolstop.co.uk/eclipse-e11r ... mcnHabc1pc ?

5. Metal brake https://www.ebay.co.uk/itm/333582823510

6. Helmet https://www.ebay.co.uk/itm/382826243041 ... 1524816121

7. Magnets? I can't figure out which are good or bad.

Can I get by without the air tools?

Where should I source the sheet metal, and does it need any particular spec besides the thickness?

[Lumphammer]

You've got some really nice kit there! Should be great!

The clamps you listed are good but you only need a couple of big ones, the ones you listed are quite big but they will come in handy - get some smaller 6" ones, but lots of them. I've got probably 12+ welding clamps and there are times i use all of them. If it helps lidl currently have 3pk's of welding clamps in

I've found a couple of woodworking clamps where you can reverse the jaws and make them push are very useful. Like these but mine are cheap versions from lidl. Obviously don't let the ends get hot - https://www.screwfix.com/p/irwin-quick- ... r-12/86306

Magnets I've got two big ones like these https://www.toolstation.com/sip-univers ... der/p48436 and a four pack of the small ones you can get on ebay. Very useful for lining up the outer wing when you come to fit it

You don't need air tools, they are occasionaly useful and you find use for them when you have them. If you have a dremel that might come in handy.

For steel you want bog standard ungalvanised mild steel sheet. Ideally 1.0mm and 1.5mm. I have some 0.7mm but I wouldn't bother just use 1.0mm as 0.7mm is a PITA to work with. Google steel stockholders near you and give them a call - say you want mild steel sheet for car body repair.

A full sheet is 2m x 1m but most will sell you a half sheet and maybe 1m x 0.5m. My car is a rot box so i've got to do a lot - i reckon i'll use a half sheet of 1.0mm and not even a quarter sheet of 1.5mm but I did get the floor to sill pieces made up separately

50mm wire mops for the drill are useful in tight spaces

If budget will stretch I'd highly recommend a finger sander and 40 grit papers

[Lumphammer]

The chassis rails being the box sections that run under the floorpan?

[Lumphammer]

You want nothing but 0.6mm wire and the corresponding 0.6mm tips, the shoud is the same so what you have is fine

[NeilJM]

Thanks once more!

I'll definitely get a finger sander. Looks like a fun gadget anyway :D

Yes, I don't know what they're strictly called but the sections that look like they're there to stiffen the floor. Mine aren't the worst I've seen but they could be better and one or two spots were picked up by MOT. I'm unsure yet if to patch them (say... 2 6" long sections) or just put new beefier ones in anyway if I'm there https://themx5restorer.co.uk/shop/new-m ... ssis-rail/

[Lumphammer]

Yes that's them. I replaced the ones on my Mk1 if it's of help - Page two of this thread

viewtopic.php?f=35&t=7585&start=15

I wanted them to tuck into the end sections like the original and my panels were made up to do that. I think the mx5-restorer ones are different because they fit over the end sections. You don't need a rotisserie but you'll need to support the car on jacks in a way so it doesn't foul with the places you need to work with, the floor is thin (0.7mm i think) so you weld down onto the replacement rail sections which are thicker.

The original sections are very thin (0.7mm?) so I guessed yours are pancaked like mine were

[NeilJM]

Actually not pancaked, just rusted at the ends where they tuck under. I suppose I could just make up some short patch sections for the ends and weld them in, but I like the idea of upgrading to a good stiff rail along there anyway.

Your thread is a helpful reminder that they'll need to allow for the pipes!

[NeilJM]

Well, almost a year since my last post on this thread and I've finally started this moving again!

Seats, carpet and dash out.

DSC_0717.JPG (667.54 KiB) Viewed 1232 times

Floor is pretty clean, you can see the rusty spot welds where it's rusted from underneath, new floor rails are on the way. Went for 1.5mm with spreader plates too. (https://themx5restorer.co.uk/shop/new-m ... mk2-mk2-5/)

Some surface rust probably from water sitting inside the cabin. Now it's empty I can use the hose to see where it's getting in and sort that.

Might rebuild the seat mounting risers where I hacked them a bit for the previous seat rails, and do something cleaner now I have a welder. Maybe take the rear ones out entirely tbh, anything to get my head lower!

Also spotted some rust at the bottom of of the A pillars, I can look at that more closely once I have the wings off for the sills.

DSC_0710.JPG (563.73 KiB) Viewed 1232 times

Feels good to make progress, even if only a little!

[blackyb]

Slowly slowly wins the race and avoids cockups along the way.

Just a footnote, I dont see any images.

[NeilJM]

Oh dear, I do! I'll see what I can do...

Now?

[blackyb]

Pickies are up now buddy.

[Mazda Mender]

Nearly a year and half all mine came to a stop from being seriously let down with body shops and builders So had enough and rolled up the sleeves , made a plan off attack, so working in the back ground on storage buildings and then onto the garage to be able to start again...not stopped since Oct building , weather as been a constant battle, but hopefully another month and I start mending again,plenty to do on the projects side of things here, that's why I have been quiet on the projects, but busy as hell that I was not going to bore people with.
Keep us up to date , I love the build threads.
M-m

[blackyb]

Cant wait to see the new Bat Cave.

[Mazda Mender]

Cant wait to see the new Bat Cave.

Cave's
M-m

[NeilJM]

Thanks guys! It's a refreshing change from everyone else in the world telling us to be more productive

I'm trying to figure out if the spreader plates on top are worthwhile. I know they're not there stock, but it does make sense to add some strength and make it more of a complete box section - plus, at the front end the areas around the spots are rusted so it would need more reinforcement anyway. Is there a downside anyone can think of? Trapped moisture?