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Next Phase Complete, TR-2 has Body OFF!

Mark_Gibson

Jedi Trainee
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My best friend made me this body stand, and this morning my son and I heaved it up onto it. Now I can start learning how to MIG weld (new floors, rockers, and rear inner doglegs), and start dismantling the chassis. Looks like I'll be having some fun this winter! I managed to brace the door openings with 1/8 flat steel, bent 90 degrees so i could use existing mounting holes in the body. It's nice that the TR-2/3 has a welded strong inner sill. I don't think it will flex much while we're working on it. Thanks for all your support....pictures attached....
 

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Now I'm jelous! I have to wait till spring to pull the body off my 2. I had to make room for the wife's toy to park out of the snow, so I don't have any place to put it.
I plan to have my engine and tranny all ready by spring time so at least I'll be buisy.
Hey, any chance I could get you to make a cardboard template of the front inner fender profile (the curve it has looking at the side of it)?
My car has taken a hit to the front and both the fenders and inner fenders are tweaked, so I dont have anything to go by to straighten them out.
Lookin great Mark!
 
Hi Mark,
Looking great! I pulled the body off of my 60 3 and had a body shop take care of all of the rust, cockpit floors, trunk floor, back "seat" floor, inner and outer rocker panels etc, etc. He then painted it BRG and it was great, until I put it back on the frame and tried aligning doors, trunk lid, hood, fenders etc. What a nightmare. After cutting stuff apart and re-welding different joints and ruining the paint job in the process I have gotten everything aligned to my satisfaction. Did I mention it was a nightmare? Not to mention extremely demoralising. The project actually languished for 10 years before I could bring myself to get back to it. So, my advice to you is to kep doors and other panels nearby so you can check alignment and clearances while you have things tacked, and are able to adjust. That is probably all pretty basic, but my (former) body guy sure missed it.
Have fun and keep the pictures coming.
Tim
 
Thanks for the advice Tim, I will definitely do that! It will be up to my body shop to fit the body back on the chassis once I:

Have my brother in law help me weld in new floors, rockers, and rear doglegs for the inner fenders

Take the body to have it media blasted

Strip the frame and have it blasted and powder coated gloss black

Rebuild the suspension, etc, etc...

I'm going to have some fun this winter!

Banjo..I will definitely trace out the pattern for the front inner fenders, send me your address my friend!

Take care,
 
Hi Mark,

Tim's unhappy experience makes some very good points and you can do a few things to avoid those sorts of problems.

Looking at your pics, the braces in the door openings look good. You might also want to add a cross brace from side to side, and possibly a strap down from the center of that to the driveshaft tunnel to support the center of the tub. Also optional, diagonal straps in the door openings can help keep things square.

First thing I'd do is clean up and repair the frame, checking that it's solid and good and square, against the dimensions given in the service manuals. You might have the frame media blasted now and temporarily painted with weld-through primer, then go over it carefully to check the integrety of all the original welds, do any reinforcement or repairs that are needed. Don't put a final paint job or powdercoating on the frame yet. Before that, there's more to consider.

1. TR bodies were undoubtedly built on jigs, then eventually married up to the frame, suspension and drivetrain that were pre-assembled elsewhere. Since none of us have jigs to work with, the frame has to serve as one. So, temporarily reinstall the body on the frame before cutting and removing any old panels, especially those you that you need to replace. Leave the body on the frame while fitting, installing and through most (if not all) of the welding of new panels. Frequently check the fit of the new panels by reinstalling various adjacent bolt-on panels.

2. Work on one side at a time. The other side can serve as a guide.

3. "Build around the doors". Directly or indirectly, they are the guide-point for all other panel fitting on TRs. Temporarily re-fit the doors and whatever else you need to, as a guide when installing those parts.

4. Tack weld, check the fit on everything, then later come back and do finish welding a little at a time while being careful not to overheat and warp any particular area.

5. TR2 and 3, in particular, have a hand made quality about them. That means some variation in assembly, nowhere nearly as rigidly controlled as modern cars rolling off a robotic assembly line. You will find new replacement panels need a good deal of fitting.

Once the body is restored, then it's time to separate it from the frame again and strip them both for a trip to the media blaster. Just before it's trip to the blaster is when the body and frame look their ugliest and most derelict, even though you know everything is perfectly aligned and ready for the next step!

Back on the body, use soda or plastic media blasting on all the flat panels to avoid any warpage.

If media blasting shows up any smaller rusted areas in the body, those might be repaired by welding in a smaller patch panels, without necessarily needing to reinstall the body on the frame and go through the trial fitting again. However before final painting, I'd be very tempted to do another trial fit of the body onto the frame and bolt-on key pieces onto the body as well, in case anything needs some a little work before the final finish goes on. Like Tim said, there's nothing worse than having to destroy part of a brand new paint job during reassembly!

It can be a very fun job! But doing things in the wrong order and not doing *a lot* of trial fitting along the way nearly always leads to very frustrating problems later!
 
Alan,
Excellent commentary. Have you thought of formalizing it and submitting it to the knowlage base. (or did I miss that it's already there)
That is some very good "been there-done that" advice and it's right on the money.
 
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