TR2/3/3A Rear sheetmetal repair

[sp53]

Looks great Frank, the car will be beautiful and fun to drive. Marv, how much for the Jag?

 

[DavidApp]

I am not a sheet metal worker but I watched his entire series on the E Type bonnet just amazed at his skill and the way he explains what he is doing.

David

 

[Frank Canale]

Yes it is obvious he has been doing it for a long time. He like lionel are one with the metal. They have that 3D eye that lets them know which way the metal needs to move. The more I work with it it does seem that some repairs go a little faster. My repairs take so much longer because mine have to fit so much better than if it was MIG welded, but I save a little time not having all the grinding and I hate grinding. I will take a little more time to keep from having to do the grinding. Speaking of grinding I have run into a stubborn rear closing panel. The spot welds are difficult to find and are very good so they are holding on for dear life. I don't want to damage the spare tire compartment as it is one of the few places that is not rusted. Once I get it removed I can continue with repairs to the rear apron. Frank

 

[LionelJrudd]

Wonderful to see the standard of work you are doing Frank. I have been out of the loop for a while and it seems you have moved ahead in leaps and bounds. Lionel

 

[Frank Canale]

Great to hear from you,Lionel. Hope you are doing well. I have been looking back at your post and pictures. They have been great help and also keeps me motivated. Frank

 

[Frank Canale]

Wow, what a boost. Thank you Lionel

 

[Frank Canale]

I am a little aggravated that I did not get a good picture of the damage to the driver side rear apron before I started. I thought I had one but I guess not.
This picture is too close to show all the damage but I think you get the idea.
This is where the very back of the rear wing bolts on. The top and bottom bolts had to be cut to remove them and the cages had to be removed also. The center one may just get a new nut. I have not decided if I am going to order the heavy duty cage and nuts or use the cages and nuts that I have made. This is one area that you do not want to have a problem with the nut being able to spin.
Damage repaired
Damaged area cut out.
Ever wonder what the inside looks like? I took this picture to emphasize that both sides need to be clean before you weld. I will be figuring out how I am going to sand blast the inside and prime before I replace the new rear closing panel. Input on this subject is appreciated, sand blast media ,POR 15, Epoxy primer, rattle can primer, rust converter?
Patch ready to tack in place. Forgot to take picture of tacks. This patch was an odd shape with twist and turns and took a while to get tacked in place. I don't want anyone to think that I am a welder and so it is fast and easy for me. I have my troubles, I blow holes in my repairs and I have to fix them also. Welding this thin sheetmetal is difficult but do not give up, it takes practice and patience.
patch welded in. Repair done for now, minor hammer and dolly work remain once the passenger side is done.

The passenger side is next and it is the ugly side but now I have the driver side to go by. The entire lower corner is gone so I have some metal forming to look forward to. I have the pattern to make the rear closing panel and will get it made and out of the way but it will be a while before it will be installed after sandblasting, cage nuts, and repairs to the passenger side. Frank

 

[Tr3aguy]

****= Dang will need to hire Frank to fix up the rear of my car....nice repair/

 

[Graham H]

Looking good Frank, I left the closing panels off when I sent my body for sandblasting so they could get to the back of the rear valence and I was happy with the result.

Graham

 

[CJD]

You have become master of the compound patch! Like catching flies with chopsticks...one who masters the compound patch can accomplish anything.

 

[Frank Canale]

Thank you John. I hope you are right because I am running out of places to practice on. Most of what is coming up will be very visible so will need to be spot on.
This is the driver side wheel arch. Plenty of rust damage.
This is the top view of the driver side what I call the rear deck. Center of the wheel arch also rusted out.
Repair patch with cage nut spot welded and zink primer where the upper flanges meet. I copied the original cages and made my own stainless nuts. Modern nuts are 7/16 square and not as thick as the originals. The nuts I made are out of 304 stainless bar. The nuts are 1/2" square and .200" thick to match the originals. These are less likely to spin in the cage.
This is the driver side boot wall as it gets to the top of the wheel arch. It was easier to cut a large area out so the weld was easier to work than try and do a couple of small repairs. Getting a little more comfortable doing it this way instead of little repairs. better results.
Repair welded and finished. Inner wheel arch flange replaced.

More wheel arch flange to replace before the top of the outer wheel arch flange and rear deck area are repaired. If there is a proper name for the area that the fuel filler goes in I would love to know.I think it is referred to as the rear deck area. All of my repairs may be getting repetitive . If so I can condense it to before and after unless there is still interest in seeing the details. Thank you all for your input and encouragement. Frank

 

[Frank Canale]

damaged flange cut out ready for repair repair piece in place.

repair tacked in place. flange welded and finished. drilled for cage nut.

the driver side flange is repaired from the back to where the dog leg quarter panel meets the rear deck. I think I am going to go ahead and finish the flange all the way to the bottom. This is slow tedious work but I want to go ahead and get the driver side a little farther along before I flip it over to work on the passenger side. Frank

 

[Frank Canale]

UPDATE, been a little lazy posting as I go so I will try and do quick post to get up to date. Wheel arch repair was boring but will look to see if there are any good pictures to post.
Driver side before
Driver side after. This area is very tight to get a dolly in to planish the weld, but came out ok. Frank

 

[Tr3aguy]

Amazing Work Frank....looking good

 

[sp53]

Frank if that car could talk it would thank you another chance.

 

[Frank Canale]

I don’t think my car has had much love for a long time. Slow going but we are getting there. Thank you for the encouraging comments.

 

[DavidApp]

Hello Frank.

Looking great. Moving right along. Working and remembering to document is tough. I found that I missed a number of shots.

You are dealing with far more rust than I had on my car.

David

 

[Graham H]

As David said you get carried away with what you have in front of you and forget to record as you go, looking good.

Graham

 

[Frank Canale]

Driver side, front, lower inner wing before
driver side, front, lower inner wing after repair
passenger side rear wing mounting flange before
passenger side rear wing mounting flange replaced with new cages and stainless nuts

More to come. Frank

 

[LionelJrudd]

Wonderful work Frank. You have come a long way since your first photos.
lionel