The Super Duper Haggis Hauler

[MacQuigley]

My wife would say "Whats for you will no go by you"!

To that I say Thrrrrrrrrrrrrrrrrrup! (thats a big blown rasberry just in case its not obvious)

I love her, but she talks crap!

Lotus Cortina. Thats more painful than the Camaro!

[MacQuigley]

Quick question, If Im fitting a fill outer floor and rocker do I need to fit the inner rocker panel as well or does the outer part of the floor patch panel act as the inner rocker?

[ibrown50]

Bill if your floor repair panels look like this then they incorporater the inner rocker,



The outer rocker fits over like this

[MacQuigley]

Thats what Ive got Ian. Wasnt until Id finished welding the floor in this morning and started to offer up the rocker that I started to have second thoughts about using the inner rocker.

Still have one problem. The inner rocker (on the floor secton) is about 11cm deep at the rear and less than 10 at the front therefore doesnt fully enclose the outer. So I may need to use the inner rocker patch panels I bought to filly box it all in.

[ibrown50]

I drilled and plug welded the outer rocker all the way around including the top, mine lined up perfectly with the inner rocker along the underside, the biggest issue I had was getting the door gap right along the bottom..



After drilling the outer if fitted it and marked where the spots welds would be took it off and sanded just enough of the e-coat primer off the let me weld it



and then after welding dressed it with a bull nosed carbide burr, that way you can leave a little indentation which looks like a factory spot weld once you've painted it.

[MacQuigley]

How the day started



And how its just finished



Progress!

Tomorrow I'll follow in Ian's steps and get the rocker on.

BTW checked the passenger side floor patch panel and the inner rocker there is a different size, though at least its the same at both ends.

[MacQuigley]

With the rocker tacked in place and the door hung everything looks just about OK.

Th egap at the bottom isnt quite even but I thing I can sort that. Thing is do I repair the door now before fully wellding up the rocker?

As the picture shows the corner of the door has been puller out slightly. So I think Its probably a better idea it fix that now befor I weld up the rocker and find I have to adjust it (slightly - as there is little movement anyway!).

[MacQuigley]

As Kirk said to McCoy in Star Trek 3 "my god bones what have I done?"

I know how he felt (or feels as its 300 year in the future!!!)?



Kirk of course had just blown up the Enterprise!

However unlike Kirk I have to put this back together and I dont have a Scotty!

Oh wait! Im from Scotland, hopefully thats a good omen!

That said, It just dawned on me 30 minutes ago that I forgot to bolt the inner rocker and cab suport together before I tacked the outer rocker in place.

Oh well I guess thats getting ground off tomorrow. I guess I knew that hence I only tacked it in place...........

One step foreward, 3 steps back!!!!!!!!!!

BTW the photo was after much shot blasting and chemical treatment.

It really looked like crap before!



My wee shotblast pot is good but its not great. Ideal for the like of this where I cant get in with an angle grinder but it takes time even with 270ltr of air.

[Grizz1963]

Amazing resilience Bill.

You really are knocking it out the park.

[Johnny_Lamebridge]

Nice work! What you had to begin with was pretty ugly.

[MacQuigley]

Well the door’s not finished yet. The main reason is I decided to do the job properly (well!!!!) and fill the speaker hole a PO had cut (Im sure he used tin snips).

So I used the swage line from the section I cut from the bottom of the door and filled the hole (the last wee bit I will fill with filler/bondo though I did use another part of the swage line behind it to part fill the hole).

It will need some serious filling and sanding but I think it will look good in the end, certainly much better than it did to start.





Hopefully get the skin on tomorrow.

Oh and I did sand blast that last portion before giving it a good coat of epoxy. I had intended just cutting it all out but Im glad I made the repairs I did, even if welding up all that REALLY thin steel was a mega pain in the Arse/Ass!

[mjh1965]

Looking good . It'll be good to see the outer skin go on . Filling in the speaker hole is well worth the extra effort.

[MacQuigley]

Agreed! Almost didn't but it looks much better. And anyway I'd only have had to fill it and make up a door card.

[ibrown50]

Nice job Bill, good idea using the old door bottom to fix the speaker hole

[MacQuigley]

Still got some welding to do but thats one side about finished!



Tell you what, these parch panels suck! I had to re drill the holes for the door mirror. It wasnt even close



Door gaps do still been some work but thats for another time.

[mjh1965]

I thought I was working in a tight space . Door is looking good it'll be in paint before you know it

[MacQuigley]

Its murder Martin!

Garage is 30' x 9' and the workshop is behind it which is roughly 13' x 18' but there is barely room to swing a cat! Not quite sure how I'll have space to paint the cab.

I also need to raise it a but as I cant get under it with a welding mask on to finish welding up the cab mount and rocker!

[Grizz1963]

You really continue to amaze and inspire Bill.

I am sure I would not give up, but man, I would be gritting my teeth most of the way.


Please take a look in my threads last page and see if you can advise any further on blasting.

Thanks, Rian.

[mjh1965]

Hi Bill
I have sent you a PM regarding Ron at STS, Grizz and I brown have both used him as well .

[MacQuigley]

Got it Martin. I'll be contacting him today hopefully.

[dug224]

Great build! Appreciate the photo documentation. dug

[MacQuigley]

Got it to upload.

Been working away on the corner and rockers over the last week. Everything is now fully welded and dome filler applied.

I had a lot of difficulty getting the outer rocker to fit at the ends. Had to cut and fit them and wil lhave to fill then to get the shap. They just didnt fit. The cab corner was much the same. Had to do some cutting, welding and filling to get it to fit.

But its all mostly there save the filling and sanding






Maybe make a start on the other side this weekend - what a thought!

[MacQuigley]

Thanks Doug. I was going to update it tonight but I cant get Photobucket to load on my PC???

[MacQuigley]

Had to take my mate down to a little village in Ayrshire today to collect his Land Rover Discovery 2 which was getting a new chassis fitted. Had a nice run in my V8 Discovery 1 and that just makes me want to get the truck finished all the more!

Anyway only had the afternoon to be getting on with it so I decided to stick with the drivers side and start some of the filling.

Still not finished yet but Im happy I'll be able to get the shape right after cutting the rocker up.



Also the cab corner is looking not too bad.




Not looking forward to sorting out "spaghetti junction" though!



And I got the last part of the rear axle stripped ie the old brakes off (half shafts and diff already out).



So tomorrow I'll make a start on the passenger side and maybe cleaning up the axle.

Also I finally got things sorted with Performance on Line so hopefully I'll be ordering my new suspension and brakes next week. Shame we voted to leave the EU yesterday. Thats cost me another 5% at least!

[Chevy Apache]

Looking good Bill go much faster be like the speed of light lol