My Hellhole Repair |
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My Hellhole Repair |
Tenner |
May 13 2019, 08:33 AM
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#1
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
As I have written before in Superhawk996 thread, I build the inner longitudinal myself. However, it took more than 6 months for me to come to a useful conclusion and 3-4 attempts with different approaches. The aim was to form the longitudinal from one piece of sheet metal to have as few welds as possible at the end. The starting point was, except for the first attempt, a 1000x500mm large, 1.2mm thick steel sheet. At the first attempt, I first put down the lower edge and then brought the rounding into the metal sheet with a stretching and compression device. At the end of the procedure, the lower edge lay flat on the repair panel of the inner wheelhouse.
In the next step, the second "edge" had to be bent. Since this edge is less an edge than a curve, I built a tool to bend the sheet. The top edge / rounding and the first attempt was done ... basically quite good, but unfortunately I had to realize that the part was a bit short. When fitting, I noticed that the sheet metal at the longitudinal in the passenger compartment was very thin. I had to cut much more out of the longitudinal. In addition, my repair sheet was 1.5mm and not as original 1.2mm. The second attempt was a single failure, too short at the front, too long at the back and too little material in the width. For the 3rd attempt, I ordered 1.2mm sheet metal and started again. Since the 1st edge already has a rather complex shape and the forming with the stretching and compression tool was a pita, I made a knocking mold out of a 1m long angle iron. The sheet metal is clamped in between and the sheet has its profile. Then the edge is shaped with a hammer. |
Tenner |
May 13 2019, 08:40 AM
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#2
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
Also very tedious, but the result is good.
The next steps I did exactly as I did on the first try. But the sheet was useless too. At the last edge (Welding to the inner wheelhouse) I confused the dimensions front / rear, so that the box in the front of the engine compartment was too wide and too narrow at the back. Stupidly, I had already cut off the excess material, otherwise I could have straightened the edge again and turn again. Despite the failures my motivation was unbroken. 3. Attempt. This time I built a second knock mold for the upper edge. In the last 3 weeks I have adapted the new repair sheet to the body, and vice versa. I started with the inner longitudinal. At the front it fits quite well. Since I wanted to save as much of the internal reinforcement as possible, I peeled off so much metal that only healthy material was left over. The overlap of internal reinforcement and the sill should be sufficient to stabilize the weld. The weld between original sills and repair panel is then hidden under the rear axle mount. After a bit of grinding and filing, the sheet was in the right place. |
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