I did it!

[Gresley]

Well done Ian, it looks great!

Brian

[Ian Durrant]

Thanks Brian,

It'll look better when its painted. The welding has blackened the metal which makes the sill repairs look a bit rough in the Pics when actually they don't look like that at all.

[Ian Durrant]

Hi Glyn,

Many many thanks for those Pics. I'll have to look at mine again and get some better pics, but I am pretty sure on mine the ribbed pressing of the floor is different and is above the outrigger flange making bringing the two together look impossible. I'll have a look tomorrow evening.

Kind regards
Ian

[XFSTag]

Hi Glyn,

Many many thanks for those Pics. I'll have to look at mine again and get some better pics, but I am pretty sure on mine the ribbed pressing of the floor is different and is above the outrigger flange making bringing the two together look impossible. I'll have a look tomorrow evening.

Kind regards
Ian

Your welcome Ian
It could be the difference in the pressings. I had the floor and the outriggers from Wards and spoke to them about how they tackle the job. Also used the Martin Thaddeus book which has a lot of good pictures of the stag floor job.
Glad I am not the only one who has been grovelling about on the floor for the past few weeks!
It's a satisfying feeling to do it yourself
I am hoping to have her taxed and on the road for June, still have some more painting to do and then refitting the inside which is stripped bare at the mo
Cheers
Glyn

[StagManiac]

Inspirational stuff, guys!

I am in the midst of a LONG-term restoration of a Stag - as in over 20 years so far! Other projects, life and university intervened. I still have the car and fully intend to return it to the road in a few years.

Seeing how you make these repairs really is invaluable to me, so please do keep the pictures coming!

Mine needs a new boot floor. Can this be done without removing the rear quarters and rear valence? My guess is that it can. Other than that, the battery box the usual boot lid rear edge and some minor repairs needed to the hard top, mine is a decent shell in grey primer at present, having been media blasted about ten years ago.

Thanks again!

Paul

[Ian Durrant]

IMG-20110505-00042.jpgI took Glyn's advice and that together with some judicious panel beating with a cross pein hammer I managed to bring the outrigger and floor much closer together. It does mean that the floor has a slight depression in it but it wiull be under that tar sound deadening when that replaced so it won't be noticeable.

The outrigger is now plug welded to the floor similar to the original construction.

[XFSTag]

Hi Ian
Well done mate
That looks a good job and will also be much stronger too with less flexing of the floor. I bought myself a cheap set of panel beating hammers from fleabay and have already got good use of them
I have just had the new floor pads from Paddocks delivered so will be fitting shortly.
More ruddy painting first
All the best
Glyn

[jamcarr2]

Looks good Ian, are you going to seal between the floor and out rigger?

[martin]

But it does leave me with a question. The new outriggers aren't shaped to the floorpan and no panel beating can correct it, so has everybody else just left a gap in the centre like on mine?

Hi, it looks as if the floor section has slightly bowed upwards, given the general quality of repair panels, I wonder if it was a fraction too wide ? Or is it an illusion ? Martin.

[Ian Durrant]

Looks good Ian, are you going to seal between the floor and out rigger?

I'll dynax inject the outrigger and that will seal the inner seam, then seam sealer on the outside. The whole floor underneath and inside the car is going to get a coat of POR15 or similar then a coat of waxoyl underseal underneath.

[Ian Durrant]

Hi, it looks as if the floor section has slightly bowed upwards, given the general quality of repair panels, I wonder if it was a fraction too wide ? Or is it an illusion ? Martin.

Hi Martin, THe floorpan panel was square so I cut the right hand side of it so the seam weld is above the main chassis rail so it wasn't too wide (or if it was I cut it to size). The problem is that the original outriggers appear to have allowed for pressings in the floorpan but this repro one doesn't.

[Ian Durrant]

IMG-20110604-00058.jpg

I have now done the other side, which wasn't half as bad.

I just patched the edge of the floorpan and seam welded in new metal after having cut out all the rot.

[Ian Durrant]

IMG-20110604-00061.jpg

The end of the outrigger has been mot welded before so I decided to cut it off and replace it

I made a cardboard template, well actually I made three the first two were just not quite right!



IMG-20110604-00060.jpg

[Ian Durrant]

IMG-20110604-00057.jpg



I forgot to take pictures of the steel cut to the template but I took some of it welded onto the car. You can also see the right angle section I made to replace the edge of the floorpan and the plug welds that hold it to the inner sill.