Gazzar Posted November 28, 2021 Share Posted November 28, 2021 It's time, I think, to sort out the foot well on the 109. I've an Wright off road mat to fit, and it's silly to just trap the rust. I can replace the whole thing, but I think I'll just do an in situ repair. I'm not sure if I've to take the wing off to achieve this. But I'm going to try to avoid that, 40 heart old fittings and all that. Some photos of "before". 1 Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 28, 2021 Author Share Posted November 28, 2021 The foot for the bulkhead isn't great either. Not sure how to tackle that. New part? Fabricate up and patch in? Quote Link to comment Share on other sites More sharing options...
Peaklander Posted November 28, 2021 Share Posted November 28, 2021 Those feet slide up inside the A post till just above the bottom hinge. They can be replaced in situ. I did one recently on my Defender but you do need the wing off. It's difficult as you need to drill out the spot welds that join it to the post and that means finding them first. Take your time and scrap the paint very carefully and you will see the spot weld tip impressions. Don't start flap wheeling or something equally aggressive as that will remove metal and hide the marks. If you need to replace the footwell then it will be a more complete job to change the A post and the post foot, all at the same time. It's just a bit of welding. I borrowed a spot welder when I did my 88" but on my 110 I puddle-welded. 1 Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 28, 2021 Author Share Posted November 28, 2021 I'm still debating whether I can ignore until the summer, but I think I need a reason to go to the workshop. I've the wing fasteners soaking in plus gas, so will start ripping tomorrow after work The drivers side is as bad, but that might wait, depends on how the passenger side goes. I'll get some feet. Anyone used epoxy aerosols? I'd like this to last.... Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 28, 2021 Author Share Posted November 28, 2021 The more I think about this, the more I'm inclined to leave till the spring. Get it though the MOT first. Quote Link to comment Share on other sites More sharing options...
Peaklander Posted November 28, 2021 Share Posted November 28, 2021 (edited) To whet your appetite and help you decide about doing it in the cold and dark or warm and sunny, here are some of my pics, on the 110 but the same job... (I said it's hard to find the welds!) EDIT: I had previously repaired the footwell with a new piece but foolishly told myself that the foot was OK Edited November 28, 2021 by Peaklander 1 Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 28, 2021 Author Share Posted November 28, 2021 It's the painting that's causing me to pause. I've fitted the workshop with air, but not invested time in learning about 2k and spray painting yet. I'll get it through the MOT, then do the work when I'm ready to paint, I can work it in with the lightweight project. Quote Link to comment Share on other sites More sharing options...
Cory Posted November 30, 2021 Share Posted November 30, 2021 Holy moly! They went crazy with the spot weld machine at the factory. Quote Link to comment Share on other sites More sharing options...
Peaklander Posted November 30, 2021 Share Posted November 30, 2021 No, I went crazy trying to find them. Some holes are my failed attempts at locating them, hence the advice about carefully revealing and not grinding metal away. 1 Quote Link to comment Share on other sites More sharing options...
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