Black Goo

I've not been looking after this here blog, and so I've decided that I'll make more of an effort to document my TR7 rebuild. The story so far...

(cue Wayne's World-style wibble effect)

I've been repairing the left hand side of the floorpan, where there was some corrosion at both the front and rear edges. This is not good, as the TR7 is a monocoque, so the floor forms part of the structure, as does most of the metalwork, to be truthful. The rear floor area is especially important, as this is close to the area where the trailing arms that hold the rear axle to the chassis bolt in.

So I've been busy - cutting out rusty metal with tinsnips and angle grinder cutting disks, and welding in new metal. I've been using both sheet steel and commercially available repair pieces as appropriate. Once the new steel was welded in, I cleaned up the remaining areas of original metal with a twisted wire cup in my trusty angle grinder, before treating any remaining surface rust with Kurust, which chemically neutralises the rust. The surface rust formed in part because the bituminous sound-deadening panels fitted at the factory were fixed to the floorpan underneath the paint, so I am hoping to prevent this by putting the replacement sound-deadening panels on top of the paint.

At the moment, I have primed the floor, using U-Pol Acid #8 etch primer aerosol and normal grey primer. The next step, which I did this evening, is to seal the seams and welds using U-Pol Tigerseal, which is a polyurethane adhesive sealant which comes in a tube.
Here's the primed front floorpan before Tigersealing:

And here it is afterwards:

Tigerseal is very gloopy, and it's hard to get it looking neat. But it's sealed the edges well, and once it's dry will be ready for paint. Hopefully, I'll get the paint done (as it's completely hidden by carpet and the like, I'm going to use a few coats of satin black) before the TR Drivers weekend at Billing Aquadrome, Northampton next weekend. Like last year, we're dragging out the tent and will be camping all weekend. The car will be there next year, honest...

TR7 Progress

A wee note about progress on the TR7.

• LH Door is reskinned, awaiting fitting and tweaking (which I will do once the floor on the LH side is completed). It also needs seam sealing inside.
• The LH front floor is practically complete. All I need to do is dress the plug welds, and get rid of the remaining surface rust on the interior before giving the bare metal a temporary coat of primer.
• The quarterlight frame for the LH door needs starting again, as there's some surace rust reappearing. It needs stripping, derusting and repainting.
• I have enough parts to repair the LH rear floor.
  
• I have rebuilt the LH rear drum brake, and have some parts to re-build the RH rear drum brake. I only need to rebuild the brakes enough now to ensure the handbrake works, as I plan to pull the rear axle out. This is so I can turn the car round on my slopy drive so I can fix the floor on the RH side.
  
• The bumpers are in the process of being refurbed - they need stripping down, derusting and the plastic parts repainting. I need two new sidelight assemblies - the fixing bolts were seized and broke on both of them, as well as a replacement front centre bumper cover.
  

That'll do for now...

One down, one to go...

I've finally finished replacing the left door skin on my TR7! Last step was welding the top edges, adding a little sliver of metal where I accidentally cut the frame too much when removing the old skin. Next time, cut through the frame, not the skin...

I had a few problems with my welder spluttering and popping. I thought it might be due to my clumsiness or the 28 year old steel on the door frame. After I finished the door, I went back to practising on some sheet steel to get the right settings. Experimenting with the wire speed resulted in a couple of pretty perfect welds, with a nice buzzing sound and good penetration. I've got a picture on my phone, which I'll upload later (if I remember).

Trouble is, I think my cheapo auto-darkening helmet is taking too long to react. My eyes are sensitive at the best of times (I can get arc eye - or what feels like it - on a bright sunny day), so I think I'll look into getting a new helmet.