Mini ST Hotrod

[MiniDave]

I decided to replace the rear panel in it's entirety, based partly on a recommendation from Dan - who pretty much knows about these things! I had another way to go , and I had panels for either choice....

First choice was to simply cut off the bottom, rusty bits and replace them with a panel made for that repair, in hindsight it might have been easier than drilling out all the spot welds and cleaning up that mess, but like I said....I think replacing the whole panel will give a better final result. I hope so at least.

1st pic is of the three repair panels, next pic shows the whole a panel removed.....I need to clean up any left over seam sealer and I'll need to get the flap disc after the remaining bits so I have a smooth seam to weld to. I also need to clean the e-coat off the joining surfaces of the new panel, and spray a little weld thru primer, then I'll be ready to weld er up.

I left a little at the top on the c pillars, I'll clamp the panel up in place then slice that for a clean joint.

[MiniDave]

1st test fit of the new panel....still a little trimming and clean up to do before I drag out the welder. I had hoped to get it welded on today cause the weather's been perfect.....mid 70's and dry. Tomorrow it's supposed to rain!......I also need to make a thousand holes to plug weld thru!

[MiniDave]

I've been going slow on this project, mostly because I don't really know what I'm doing! 

Also, I don't want to weld something up only to have to tear it apart again, so I'm trying to make sure I'm doing this in a logical order that will all come together in the end.

So I marked where I need to drill holes to plug weld the rear panel on, basically everywhere there wasn't a spot weld from before.

Then I decided it would be a good idea to clamp up the valance panel to make sure everything was square and fit the rear panel and the rest of the body. Before I did that I decided to weld the boot floor edge on first, that stiffens up the valance panel and gives something solid to weld the back panel to.

So I drilled a million little holes to plug weld the two together, bolted them up using the bumper attachment holes and filled in the holes with plug welds. So far so good, it still fits up nicely.

Next I needed to weld in the closing panels, but first I had to modify them as they no longer can go where they did originally - I had to make room for the subframe to be able to go in and out. Once this stuff is all welded together on the car I'll build some bolt-in brackets for the lower part of the subframe to attach to these panels. One end is done and I'll get started on the other later today.

This sheet metal is pretty thin so I have to be careful welding it together that I don't blow holes in it....so far I've been lucky. Once everything is welded up on the valance I'll clean up all the welds and give it a coat of weld thru primer before I attach it to the rear panel. I also need to cut out the left side wheel opening and remove the inner wheel well.

Then the next thing will be to weld those inner wheel wells in and tie it all back to the rear panel.

From there I'll move forward to repairing the floors and sills. I've got a really long way to go on this project, and I just need to get on with it!

[94touring]

You certainly have more than enough plug welds lol.  Because of the strength of a plug weld vs the factory spot welds if anything I space them out a little wider.  I did get a chuckle looking at the valance closing panel where you have 8 beefy plug welds and the factory uses 3 wimpy spot welds.  But, it's certainly not coming apart!! Usually anytime I'm done with welding a car back together I pity anyone who might have to try and break it down on some other restoration 50 years from now. I've had cars in my shop where someone or some shop used their own personal spot welder to add sills or front end panels and I could literally peel them off by hand. 

[MiniDave]

Ha!

I pop one in about every inch but you're right.....it's a bunch!

Now I have to go and grind all the nubs down on the valance so that it will fit up tightly against the rear panel. But first I'm going to cut out the other wheel well and opening, then I'll start welding it all together.

At least, that's the plan!