Early Javelin Restoration

[Grumpy Northener]

Outrigger welded in

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Floor repair now made good and spot welded to the new outrigger

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I have to say that by a mile the best thing in our workshop is the chassis tilter - it becomes childsplay when you need to alter the angle or get to the underside of what you are doing - I would highly recommend it should you be undertaking a restoration of this scale

[Grumpy Northener]

The Javelin shell has over 80 captive 1/4 BSF nuts which are utilised to retain the main floor & boot floor panels (ply sheet) plus the front & back wings - several studs / nuts had to be cut off due to being seized along with the fact that the metal cage that retains the nuts rust out - after much internet trawling - a supplier was located - but at 50 pence each for a bit of bent metal - well at least I only have about 20 to replace and not all 80

Old captive nut cage & new captive nut cage

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New captive nut cages spotwelded in situ

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Retaining screws trialed - ply floor pan fits into rebate and is supported by main chassis rails - New outrigger can be seen (grey primer) between chassis & sill

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[Grumpy Northener]

Last job on the A post was the area of rot at the top of the post that carries one of 3 side mountings for the front wing

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The bracket was removed and the area cut back to sound metal which in turn was made good with new metal - cleaned up and the bracket reattached

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[Grumpy Northener]

Centre outrigger was next on the list which is also the jacking point for the factory supplied jack

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The jacking tube had been overplated which in turn had just rusted from the inside out whilst the majority of the outrigger was solid - the plan was to replace all of it with a club spares supplied new one

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The exhaust pipe travels through the hole in the outrigger but before I removed the old one both of the B posts were braced with some 50 x 25 box section

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[Grumpy Northener]

The outrigger which is welded to the chassis rail also picks up the sill at the centre of the car whilst also supporting the B post

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Once removed it revealed the rusted out area of the sill to the underside of the B post - only one course of action then

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First I put some heat over the area to remove the lead that had been leveled over the recessed welds to the B post

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then the area was cut out & removed from under the B post

[Grumpy Northener]

A new section was fabricated up and tacked in

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Alignment of the B post was checked before final welding commenced

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The door hinge from which both doors hang was also trialed for fit at the same time

[Grumpy Northener]

The outrigger was checked for fit but remains to be welded in

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The jack was also checked to ensure that it does not foul the sill edge

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[Grumpy Northener]

Couple of tricks I use to make the process easy - they are just simple timesavers - for template profiles I use a short length of welding wire and just bend it shape with a pair of pliers

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To prevent burn through when welding between repairs / panels - especially if you have a small gap - use a peice of copper plate on the underside of the weld - this in turn prevents the burn through and the weld will not attach to the copper plate - it also results a flush weld on the underside and minimum dressing of the join

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Apologies for stating the obvious to those who are already aware of the above - but if it helps just one of you out - then it's been worth posting

[Topaz]

Couple of tricks I use to make the process easy - they are just simple timesavers

. . . if it helps just one of you out - then it's been worth posting

Good ideas there which have helped me so thanks for that

Mike

[Grumpy Northener]

The B post retains the hinge hanger for both of the doors - the lower hanger had been messed about with and we just happened to have a new one in the botom of a box of hinge spares - they are alloy so they tend to desolve a little being encased in a steel B post - first I had to dress the apperture for the hanger where the sill / B post repair had been undertaken

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The club spares department had located a source of the correct screws for the hanger

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The post hanger and the door hanger then have a small bush placed between them which completes the hinge setup once the pin is located

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