Mk1 NA***RESTORATION***

[John&Luke]

Latest update and latest garage TOY.

So removed my engine and gearbox as part of my restoration, new clutch, belts water pump on the “to do list”.

With just the rolling chassis left the day started like this.

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And ended up like this!

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Now a pleasure to work on all those dirty underside bits. First job is to complete the drivers side sill replacement. Can’t wait

[Mazda Mender]

M-m

[Zed.]

I've got an older version of this rollover-frame type, probably had it for ~30 years & it was secondhand when I bought it
more manual to 'tip', not used for a few years but theres a lot of tooling in my garage awaiting their use...

Rich.

[John&Luke]

Happy New Year to all Menders!!!

A few months away from the project. But now back on it

Continuing with the drivers side sill replacement. Starting at the front of the car, I cut out the rotten metal and then gave the remaining steel a good dose of rust inhibitor. Then fabricated the bottom sill section welded this and then fab’d the internal stiffening section. Nice to take my time and attempt to copy the original design as much as I can. Everything then painted prior to welding.

Then weld everything up.
Pleased with my efforts.

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[storm]

Happy New Year to all Menders!!!

A few months away from the project. But now back on it

Continuing with the drivers side sill replacement. Starting at the front of the car, I cut out the rotten metal and then gave the remaining steel a good dose of rust inhibitor. Then fabricated the bottom sill section welded this and then fab’d the internal stiffening section. Nice to take my time and attempt to copy the original design as much as I can. Everything then painted prior to welding.

Then weld everything up.
Pleased with my efforts.

Enjoying the art involved in real bodywork rather than just slapping on a shop bought panel. Reminds me of the work done on my aircooled vws back home. Keep up the awesome work bud amd keep sharing pics.

[Mazda Mender]

Passion and love in this thread i am following
M-m

[John&Luke]

Haven’t forgot my White project. In between all the other stuff, I have made some progress.

Having attacked the front of the sill my attention turned to the back.

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All hand made replacement bits , top tip is to make a template out of thin cardboard for any replacement parts before committing to metal. Scissors and card. Get it wrong stick on more card or masking tape until right, only then commit to metal.

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Then fire up the welder

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Then the outer sill
Cut, fit, spot weld and the full weld. Grind welds back and etch primer.

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Chuffed with my progress, outer archer next.

[Mazda Mender]

M-m

[John&Luke]

With the sill on, next job is to remove the remaining outer wheel arch. I have made a simple jig in order to mark cut lines on the existing arch and the replacement arch to ensure I get the required overlap to for a joggled edge ready for welding.

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My prefer method of removing the existing wheel arch from the inner is to form vertical cut lines. Being careful not to cut through the inner arch and peel back the outer arch. Using a drill or grinder to release the spot welds. See below.

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This arch wasn’t to bad. But as I’ve gone to the trouble of exposing the inner arch thought it would be false economy not to replace the inner arch lip. Not a great photo but you can just see the new metal on the RHS as I work my way around the arch.

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[blackyb]

A a bit out of my league, some good work going on here.

[GlennyGills]

Excellent work. Keep it going

[John&Luke]

Inner arch now fabricated and welded into position and primed. Existing outer arch edge joggled in order to provide a nice interface to weld to. Several trial fits in order to fettle the fit. All areas to be welded then treated to a good coat of weld through primer. Other areas sprayed with cold galvanising zine rattle can.

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Then door refitted so that I could check the shut lines and side crease alignment before welding on the outer skin. This is an important step as any misaligned of the crease would stand out a mile and be uncorrectable once the outer skin was weld on.

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Nice photo of the vertical and horizontal alignment above. And along the crease below.

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Everything looks good and straight. Already to start the process of tack welding the outer skin. Hopefully a weekend job if time allows.

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[Mazda Mender]

M-,m

[John&Luke]

So found a couple of hours tonight to weld the outer arch in place.All good.

Just need to spot weld the inner arch to the outer arch then ready for filler.

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Small bit of rot in the front arch dealt with by welding a small plate in place.

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[John&Luke]

Managed a quick hour today. So spot welded the rear arch return (factory style) and then first coat of filler.

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