Wow what a lucky, lucky car.....that would have most certainly been destined for the scrap heap in anyone elses hands!

Really enjoying reading this write-up - your thoroughness is really impressive & informative. Can't wait to see more!!!

Despite the busy season up to the holidays, I've managed to eek out a couple more hours in the workshop. I've also managed to disguise some purchasing as 'early Christmas presents' which have so far gone un-noticed...

I decided there was plenty of 'meat' left on the original trailing arm bracket, so I am going to re-use this. Here I've straightened out the separated parts using heat, 15mm plate, a HUGE ball pein hammer and a box and pan folder...

Attachment 42263

Now it's pretty much it's original shape, I'm going to make up a pattern from the original using some brown masking paper...

Attachment 42264

Attachment 42265
Now the information is accurately recorded, I'm going to transfer it onto some 'Zintec' steel to make the blank for cutting...

Attachment 42266

I'll tidy it up now ready for cutting...

Attachment 42267

While I'm still faffing about making up the new panels and repairing the floor section, I've ordered a spot weld gun. Rather than cut a big access hole in the wheel well for the big spot welder and extension arms, I'm hoping this single electrode unit will be man enough for the job of stitching it all back together. Hopefully it will arrive in time..

Attachment 42268

I also ordered an imperial 11/16th hole cutter so I can mount the original captive nuts...

Attachment 42269

Finally, I couldn't resist these eBay gems at £50 each. I'll digsuise them in the meantime as serving platters?...

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Ooooo I like that spot welder!

I just took delivery of it today and have yet to try it out, but in the meantime there is more info about it here:

http://www.ebay.co.uk/itm/Spot-Weld-...item2317b6ba43

Regards,

Gordon

That looks cool. How hard is it to get replacement sticks for it? It says they are special formula carbon arc 'pencils'.

I would love to hear how it goes, because I can think of a heap of jobs where that would be handy.

Edit:
Found this:
http://www.youtube.com/watch?v=fn2LLrNvBZI

They seem to be called 'Poke Welders'. I like the idea that it can plug into your existing arc welder.

OK, a couple of little shortcomings already, but nothing that can't be sorted...

1.) The unit comes without a 'Dinse' type connector, but you can get these from eBay for about £5. I've borrowed one from an old stick welder for the time being which should be enough to test the units effectiveness. You should get a 35 - 50 watt one otherwise on the larger rated ones the grub screw won't be long enough to grip the terminal. I've packed mine out with some crushed copper tube in the meantime.

2.) There is only 3ft of cable with the unit. This will be enough to test it out, but really pants of you are hoping to get in to a tight spot under a dashboard! I'm going to have to replace / upgrade this as I think th e original might get quite hot with the kind of use I'm hoping to get out of it.

I'm using my AC/DC TIG unit as a power supply. I'll have to be very careful to remember to reverse the polarity on the terminals (TIG uses +ve earth) and keep the amp setting strictly to within the guidlines...

Attachment 42382

I'm going to test it tomorrow as I'm really bushed now.
I've got the boys all day tomorrow so this is subect to if I can get them occupied long enough to get into the workshop....

Well, I'm going to need a bit more practice as I'd like to make sure that everything is solid around this area where the link rods mount. I've managed to get a decent penetration welding 1mm mild steel to 1.4 mm Zintec. I'll try the other way around, but at least there is potential. It's all a matter of adjusting the timing and releasing of the electrode and therefore the time of exposure to the arc...

Weld from the 1mm side...

Attachment 42409

The penetration visible from the Zintec side...

Attachment 42410

How does it compare to plug welding?