You'll be starting an auto-refurb business at this rate !!! :auto-car: No chance. By the time I have finished this I will be well sick of it. I've inhaled enough rust to last a lifetime. The aim is to keep this on the road for another 18 years when I will be ready to retire. Actually, my body says ...

It's funny the things you can cobble together as a former for bending steel. Here we have two old drainage pipes sat on a table with 56lb weights clamped between them. A few bits of wood to get the centre height right. Another two 56lb weights go on top of the work piece to stop it moving. https://i...

Moved on to the offside rear arch. In some ways it isn't as bad as the nearside but others it is worse. There are always more puddles to go through on the passenger side but less to wash winter salt away on the drivers side. Angle grinder has a mind of its own. Some of the floor needed to go too. ht...

With steel that thick and wide, does it take a lot of force or hammering to get it shaped round the wooden former? I'd also expect a bit of springback. But then I guess we're not looking at ultra-accuracy here. Some sort of (CNC) flame or plasma cutter would save a lot of time, but cost ££££'s. Or ...

Some more steel cut and inserted. Held on with little magnets until I get the welder warmed up. The grey paint is a special etch primer which can be welded through. You have to remove a bit to strike an arc but it doesn't ignite or contaminate the weld. Had to be done to stop the new steel sheet fro...

CN211276 wrote: ↑Mon Mar 11, 2024 6:50 am I will have to wait until I am back in the UK to open the photos.

You'll probably find them as boring as woodworm. It's just a 26 year old 4x4 getting bodged to within an inch of its life.

What tools have you been using to cut and bend the new metal? Cutting was done with either a metal chop saw with 12" blade or a 115mm angle grinder with 1mm thick cutting discs. If you cut right through in one place as deep as you can and then progress along your marked line it seems to be ver...

What tools have you been using to cut and bend the new metal? Mainly clamps, a vice, hard round bits of anything of the right curvature to bend it over, a bit of steel box section and lastly but not least a big lump hammer :lol: Also made this out of an old gate post. https://i.imgur.com/W0VhLG4.jp...

Next job was to close the gap and join the body to the new wheelarch. Not straight forward due to the curves involved. Decided on 2mm steel for this. Bit overkill but it needs using up. Going to do it in two pieces. Got one of the curves cut and it fits well. Need to cut the top to follow the body. ...

I replaced the sills at both sides 9 years ago. The originals were only made of 1mm steel and rusted from the inside out (as they all do). Initially my hand was forced as somebody ran into the side of me when they tried to overtake and I was turning right. All their fault and they owned up eventuall...