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footwell repair to do after MOT pick up

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MOT yesterday, 2 fails, drop arm nut a tad loose, now cured.

& drivers side footwell, when tester looked up from under the 110 he found a hole & rust he didn't like. so I've pulled the mats out & gave the area a good prodding & got this result, the area was plated back in Sept 2011 but hasn't survived very well.

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so bought a new repiar footwell, just wondering what you guys think would be the best way to do the repair, I was leaning to just doing the lower section cutting the new part below the pedal assembly bolt holes & having a seam weld or replace the complete area with the new part, 110 won't be going back on the road until this is sorted & back to tester for a retest.

 

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I think you’d be best cutting out as much as possible, especially at the foot/A-pillar. You may find that this isn’t in the best of shape given the hole on the pillar...

On one of my bulkheads that I repaired, I cut along the top fold to leave the servo etc in place then seam welded along. Like most bulkhead repairs once you start cutting and grinding it can get quite extensive 

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I think I can split the existing footwell out with a 1mm cutting disc & grinder discs/chisels will have to remove the floor plate [easy bit] , clutch & brake pedals & bonnet cable, & bolts for lower column bracket, & get the outer wing off fairly easily if the weather plays ball,  thinking I can slide the old footwell out & slide the new one into place then refit everything & a friend is hopefully going to weld it in place permanently.

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Looks as though you’ll need to rebuild the lip at the gearbox tunnel aperture too so that you can spot the new panel on. 

The new panels are the opposite of the replacements, the side panel sits over the footwell whereas the original is the other way around, it makes lining things up a bit more awkward if not replacing the entire footwell/side panel

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I'll have a better look at it tomorrow in daylight, the gearbox flange might be saveable, it looked alright when I had the engine out last year. 

 

reckon changing the complete panel will be the easist & quickest way.

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These may help

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38A2C6B9-602E-4019-96DB-E00ADEBBC736.thumb.jpeg.2bacd390b3702bff54b974e6d0e6e3c8.jpeg

C560B00F-9ECE-49CB-A405-DBD16C569CC7.thumb.jpeg.8830c731b4217fcf9e02d13e860040ab.jpeg

4CFDB269-FEC2-4B83-8F67-8C8CE448F859.thumb.jpeg.cb69609f4716d6dd2bf46ee2f592ae5a.jpeg

some idea of what you need to cut out for certain bits

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Made a start on removal of the right front wing & lights, but got rained off the incoming weather is forecast to get really heavy rain & stong winds & it just happens to be coming into my drive/garage first. Hopefully get back on it later or tomorrow.

 

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I have to do the very same thing to mine! 

Let us know how you get on 😊

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Get some fresh wire too. Nothing more frustrating than getting half way through to find the wire has run out..... back on the bus to the shop!

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its got half a roll on it, but yes will get another roll as well. will need a welding facemask & gloves too. 

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I've got a little Clarke Mig welder. It's a great DIY welder. Hopefully you've got yourself a bargain there.

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Welder was less than 70quid so happy with that,  

got back on it today once the rain had gone, so far right front wing, brake  servo & clutch pedal assemblies, accellerator pedal & cable all removed, door pillar is good. after lunch is steering column lower bracket & PDWA bolt, then sort out where I'm going to cut the existing footwell off. a couple of pics ---

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All the way up if it were me, get rid of the bit marked with green paint as well, looks a bit scabby :)

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I put a grinder disc over the green area, its good & shine now, got some help coming in morning.

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Finished all the cutting out & getting the new footwell to fit in snug [clamped & bolted]

next is to drill some holes to spot weld it to the door piller rear upright [under the door seal] paint the outside face & get it back in place ready to weld in.

I fitted some bolts to get it to sit where I wanted & got the steering column lower bracket temp fitted.

a few photo's 

 

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Welding if I do it will be the first since 1974 :o got the cutout metal to pratice with first, & got a couple of mates who can do decent welds for me if I bottle out.

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just be wary of the wind if your welding outside. It doesn't take much to blow the shielding gas away from your workpiece which will give you really carp porous welds.

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Bought a gas cylinder, regulator, self darkening helmet & gloves this morning ready for the welding pratice tomorrow,   didn't get much done this afternoon, had to recover a bracket that fits between footwell & inner arch & sort out where it has to fit on the new panel, got that done & a coat of primer on it, hopefully tomorrow I can do a bit of welding practice & weld this bracket on & maybe get the new panel welded to landy & start puting things back together, working outside, can't get 110 in the garage, Yes did realise about wind & the gas shielding. 

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Tried doing some practice welds on 2 scrap bits of metal, I don't think I've got the knowhow or confidence to do the welding on 110, I don't want to mess the new panel & 110 up, so getting someone to do the welding for me, hopefully get a reply, but might not be welded until thursday. 

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Fair enough, it is quite a big job to tackle for a first project. At least you have done the tedious time consuming bit already. It shouldn't take a pro long to get that fully welded in.

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