A Pillar repair

[Ian Durrant]

I know others have documented their (probably better) repairs in this tricky area, but I promised to document how I did mine using pretty primitive tools. I should have taken more pictures but it was so complicated working out how to make this complicated shape I was messing around with templates, cutting bits of steel and then deciding it wasn't the right approach and then throwing it away and starting again that in the end I just forgot. It was a whole days work just to get to where ut is now, but the sense of achievement makes it worthwhile. I went for the approach of making up two sections and welding them in separately to reduce the amount of panel beating required. In the end I made all this simply using a black and decker workbench as a folder and some cheap panel beating tools plus my MIG welder.

This is what I found under paint and filler quite a long time ago, I have been putting this repair off.
A Pillar.jpg

I had to cut away quite a bit of the wing and part of the screen surround to get to the innards that also needed repairing plus of course the rusty steel itself.
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I know Dasadrew and others have worked out that there is an inner strenghthener and I think they are right that it form part of the structural integrity higher up in the pillar but Now I have cut the rusty lace work out of the bottom of mine you can see a straight edge that isn't connected to anything and theres no evidence it ever did, in fact it wouldn't rust with a clean straight edge so it seems to me this lower part id more to do with channelling water away as much as anything
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Looking at the A pillar from underneath you can see its pretty solid so I only need to repair the Inner structure not make it from scratch thankfully
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More to come....

[Ian Durrant]

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This is where I failed to take pictures. I made up a patch for the inner which a simple patch with a 90 degree bend in it to repair the inner strengthener come gutter. Then I worked out how to cut a template in cardboard with a single fold and a dart cut out that I could weld in, I tried to find the template but its nowhere to be found. If I find it i'll add it to this thread. Anyway with the inner patch welded in and the outer patch with a gentle curve bent by hand together with a welded up dart we have what you see below. I made the curve using the wide mole grips and just bent iy bit by bit till I had a pretty smooth curve

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Then I welded back the screen surround I had cut out. You can see the inner repair still through the gap between my new outer patch and the piece of screen surround that been welded back in and ground off. So I just need to make that patch with a single fold in it and I can weld back the piece of wing. Then its will be lots of cavity wax to try and make sure it doesn't happen again. Thankfully the passenger side is fine.

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[flying farmer]

This is probably the worse place to work on when it comes to rusty Stags and so does get put off as long as possible. Congratulations on finally getting it done!

Neil

[Ian Durrant]

Thanks Neil.

Glad thats nearly done, I really thought it might be beyond me without a lot more gear and a lot more practice but its turning out pretty well.

Really close to the end of the welding now, just a small patch to the boot lid and the hood well gutter and I can get it ready for paint. I worked out the other day its been five years work.... Doesnt time fly!

[mike@thenook]

Nice work Ian - you'll be on the road in time for the real sun!

[Ian Durrant]

Nice work Ian - you'll be on the road in time for the real sun!

Thanks Mike,

My aim is to get it on the road before I am 50, but thats only 13 months away....eek

[mike@thenook]

Best get a move on then!

If you need any help at any point or equipment let me know, I've got most equipment.

[new to this]

ian

nice work,they really rust in that area

dave

[m9fdb]

Top work Ian

I should drop by at some point as i know we have spoke a few times and i think I may have even sold you some bits when i was Romford.

[Ian Durrant]

Hi Darren,

I didn't buy anything from you but I did pop round to your house in my van when you had the black Stag and the white mini with pink roof in the garage.

I'll have to let you know when the stag will be out of the garage as you cant see anything when its put away the garage is too small.

Ian

[Ian Durrant]

Best get a move on then!

If you need any help at any point or equipment let me know, I've got most equipment.

Thanks Mike, that's a really kind offer.