Ulysses

Keithy wrote: It's impressive how much these cars differ/rot differently.....mines a year newer and the chassis is so much cleaner/not as rotten.....still issues to be taken care of though.


Front end looks well mate!

I need a better look at Buzzweld as I want a shiny chassis on the new car.

Its a very rusty example. a lot to do with previous owners i think! This one came from Kirby Lonsdale so i would expect a lot of road salt in the winter around there. That combined with poor cleaning mean rot i guess. Its 100% bog standard.I doubt its ever been off road or green-laning. Probably a shopping car :laugh: J999 MNY is an 57 plate and in much better condition. Wonder if there was a change in something between years?
Kiethy you mentioned somewhere that yours is/will be galvanised? could that be it?

The Buzzweld is what ive covered J999 MNY in. Its been on for about 2 years and still looks great. The RCP (Rust Control Primer) is great and i have CIO (Chassis In One) as a topcoat in satin black. Cavity wax also inside all the tricky to get at bits. Stands up to heavy pressure washing and is sort of rubbery so self heals from small cuts/bumps. Stinks and has loads of HSE warnings, so must be good stuff!

Perhaps it was an RNLI one in a previous life, they had some in that colour that would have spent their life on a beach

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Mind you, they were poverty spec. with steel wheels etc

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Riccy wrote: Kiethy you mentioned somewhere that yours is/will be galvanised? could that be it?

Bodywork is....not got to the chassis for a proper look yet.

mlines wrote: Mind you, they were poverty spec. with steel wheels etc

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Thanks for the info.Good to see the lifeguards using them

The previous owner bought this one in Jan 2013 and its a VVT JLX plus (alloys, A/C and half leather seats) according to the V5. Says 2 previous owners to me, dont know how to find out who the other was tho.

Is there any info on the galvanised body Kiethy has? Could be good info for the wiki to know if they are galv after a certain year/VIN number

More welding...

Made a start on the floor and sills. Mainly the floor :laugh:

Passenger side all cut out:


and plated up:




and the body mount bracket on the chassis needed plating up as well:


Next is the driver side, But i need to finish the sills on passenger first:


Seems like its never ending! By the look of the back area it could well end up traybacked. Floor is goosed as well as the rear arches so lots of repairs or chop it all off! Probably the same amount of work either way.

Truggy it! Honestly it is the future!

Chopped that horrible back floor out today...





Doesn't look as bad as expected under it but the bottom of the bit below the rear door (rear body mount area) is gone.

So... stripped out the rest of the rear and headlining, masking tape up for tray back :evil:

Gonna have a beer and look at the masking tape for the rest of tonight to think it over

No eBay APP ID and/or Cert ID defined in Kunena configurationWell MR ANGRY :evil: the angle grinder has got through quite a few discs today (ran out actually so early finish and shower time).





Bit more to cut off yet but wanted to go at it a bit at a time to allow for cockups. Thinking of reattaching the rear door surround to close it up so have chopped it a bit, again more to do. Should end up looking the same, but 2ft shorter and without the side windows (hopefully)!





Some sort of roll cage or internal roll bar is going to be needed. What little strength the roof had is now totally gone. I also need to source a tool to make a edge to join the two halves together. This is done with a 'Flange tool' or 'Joggler', Something like this:



This will (hopefully) allow one bit to slot inside the other for a stronger joint, then spot weld together. I was looking at the roof and there is the drainage channel with the black plastic trim in it. I couldnt work out what to do with that to still keep the drain, unless its just a case of close it off and make sure you park with the nose downhill on rainy days to drain to the windscreen end :laugh:

Whoa....you're getting stuck in Rich!

Roof will be strengthened at the time you reattach the rear panel.....edge setter will ruin your panel on the curve....beware.

I trimmed the 3 skins to be planar (level) and made a 16G panel with holes to tie all 3 together.....stronger than the original.




The straight line and lack of closure at the rear lower section of the cab is something I've never liked.....plastic trim?

Cheated on the roof....welded a panel in.

Hi Kiethy, yes thats the look I'm trying to achieve with the cab back. I thought of butt jointing the curved bits and staggering the flatter sections to use the flange tool for that bit.

For the bottom bit i was thinking of making some plates to patch in. Depends how big a hole to fill. maybe fibreglass, time will tell. A fair bit off that yet tho!

Thinking about some sort of roll cage to strengthen my inept welding. Theres someone on ebay that will bend to order some pretty heavy tubing