Ulysses

Nice job mate well done 

Dirtbird, yes those are the ones. If you go for the Tecarc branded version in the UK they are £770 from welding supplies direct . Still a substantial chunk of cash if you don't use it on a regular basis.

Riccy, that's a really nice solid looking repair. It should outlast the rest of the vehicle.

back one finished off today. Made a C section bit of steel to fill in the rear skin I had chopped off and drilled some large holes in the skin to allow cavity wax to go in and dampness to evaporate out. 2 coats of buzzweld RCP and leave to dry. Turned it round and onto ramps to have a look at doing the front two (or at least make a start on them) tomorrow. 

 

Nice work mate, looks like you saved it....

sniper

We always have faith in your ability to keep ulysses going.

Decided to tackle the driver side one first. Cut a hole in the floor and slowly made it bigger until I found metal solid enough to weld to. The body mount pin was detatched from the outer skin and resting on the inner, same as the rear. 

Cut some profile from a bit of 50x100 box but couldnt get it to fit well and its shape was wrong for the job really:

 

Time for lunch and a think. Decided to start again with some 3mm flat bar I had. Much messing about to get it the right shape to fit fairly snug and then weld-a-thon to stick it in place. Need to patch the floor back in again but I'm happy that its solid enough now. Next weekend to finish off this and the other front one, then an outing on 10th to look forwards to around Penrith/Alston area.

 

 

Looking good. By the way, when spraying cavity wax I find it helps to thin it with 10-20% white spirit. This helps it soak into thin gaps.

You had better get them "gaps" filled in or else the river crossings could be exciting for you and Ulysses

Finished off the driver side this afternoon. Welded in some more galv 2mm plate to fix the floor, doused everything in rust convertor then seam sealer and RCP paint. Ive bolted it down and all seems well. Just the passenger footwell to do tomorrow. saving the easiest til last  

 

 

Nice. You're certainly cracking on with it.

Because he's on a ticking clock ... we're out Green Laning on 10th October

Plenty of time 

front passenger sorted out today. A mirror of job done on the driver side one. all liberally gunged up with seam sealer and RCP primer. I just need to stick it back together and refit some interior on friday/saturday and im good for 'laning on the 10th