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Replacement door pillars, aluminum?

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1960AH_Pops

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Hello all,

I am almost finished with the sandblasting on my BT7, I will have to do some metal work. When I pulled the car from the garage I saw that my Dad must have had this rust when he stored the car 21 years ago because there are replacement panels already there. They look to be aluminum, how do you replace them, I was under the impression you cant weld aluminum to steel. I definitly want it to be done right, I just dont know what right is at this point. Advise is appreciated.
Thanks
Chris
 
How about a couple of pictures? The entire chassis is steel. No aluminum in the chassis. The front and rear shrouds are aluminum, but they are attached with bolts and rivets, not welds. Most fenders are steel, but there are such things as aluminum fenders. Far as I know, doors are all steel. You are right, aluminum can't be welded to steel. Fortunately, most body and chassis parts are available new, as is a complete new chassis, if desired. What Dave is talking about are the finishing pieces on the rockers, sills and shut face. These are decorative only, not structural, and do attach with screws.
 
Dave Russell said:
The only parts fitting your description & made of aluminum are shown as Item 1, here:
https://www.mossmotors.com/Shop/ViewProducts.aspx?PlateIndexID=28959

If this is the part, embossed pattern aluminum, they are attached with small metal screws Item 2.

There are very good detailed parts identifications on the Moss site. If you refer to these parts by item number & description, we are all on the same page.
D
Click to expand...


Dave,

That is exactly what I am talking about. I wasn’t sure exactly how to replace the rusted ones out. I was under the impression that I was going to have to cut the old ones out and weld the new aluminum ones in.

If it is like Cutlass said then I get it that they are only for looks. My problem is the original parts are rusted pretty bad. I dont want to just cover it up though, I want to fix it the correct way.

I will try to get some pictures tonight of what I am working with, I would really appreaciate it if after I posted the pics then someone could guide me to the actual replacement parts I will need.

EDIT https://www.mossmotors.com/Shop/ViewProducts.aspx?PlateIndexID=28952
This is what I was looking for, part #60 and #28, I was under the impression that the aluminum ones I found in the garage were the replacement parts. Now I see these are the replacement parts.
Thanks
Chris
 
Chris, it would be helpful if you could be a bit more specific with your descriptions. Part numbers 60 and 28 are steel, never aluminum. Aluminum does corrode, but aluminum corrosion is not called rust. Rust is the generic word for iron oxide, the product of iron (the main component of steel) corrosion. Rust will appear reddish in color, while aluminum corrosion (aluminum oxide) will be white. A handy refrigerator magnet will help you identify questionable material. It will stick to steel, but not to aluminum. A magnet often will be mildly attracted to stainless steel, but there's not much of that on a Healey. Lots of the Healey trim is chrome plated brass, such as the windshield frame, and the magnet will not be attracted there either.

Now, with that out of the way, it appears that your problem is not the aluminum trim, but the steel rockers and shut pillars. These can be replaced fairly easily by an experienced person, but not by someone not experienced in metal work. The potential for serious disaster here is rather substantial. That being said, please do post your pictures. That will enable all the good folks here to give you some more detailed advice.
 
Cutlass said:
Chris, it would be helpful if you could be a bit more specific with your descriptions. Part numbers 60 and 28 are steel, never aluminum. Aluminum does corrode, but aluminum corrosion is not called rust. Rust is the generic word for iron oxide, the product of iron (the main component of steel) corrosion. Rust will appear reddish in color, while aluminum corrosion (aluminum oxide) will be white. A handy refrigerator magnet will help you identify questionable material. It will stick to steel, but not to aluminum. A magnet often will be mildly attracted to stainless steel, but there's not much of that on a Healey. Lots of the Healey trim is chrome plated brass, such as the windshield frame, and the magnet will not be attracted there either.

Now, with that out of the way, it appears that your problem is not the aluminum trim, but the steel rockers and shut pillars. These can be replaced fairly easily by an experienced person, but not by someone not experienced in metal work. The potential for serious disaster here is rather substantial. That being said, please do post your pictures. That will enable all the good folks here to give you some more detailed advice.
Click to expand...

Thanks Cutlass, I think my choice of words may have been confusing. The aluminum parts I was talking about(that Dave Russell pointed out) are not on the car, they were in the garage with the car. I thought that I was going to have to replace the rusted out pillars and rockers with the aluminum parts I found in the garage. I made the mistake of thinking the aluminum was a replacement for the rusted metal. After looking through Moss' site I see I need the parts I pointed out (60 and 28).
I will post some pictures this weekend, I havent been in the garage all week due to work.
Thanks for the help!
 
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