Replacing Front Valance

[Vitesse2l]

Just ordered a front valance from EJ Ward.

The car is getting a tidy up and I've been cleaning the underside and welding up the usual frilly bits. So far I've found more frill than I like but that's part of the fun. Isn't it..? Eventually it'll get  a respray, but I'm a little way off that (financially rather than timewise).

Having finished one side of the car I took my grinder to the front and found it worse than I'd hoped. The paint was only a bit flaky, but the panel wants several areas repaired and also fairly rotten all along the top flange. Taken singly, the patches are doable, but all together just too much work.

So for the first time ever I've ordering a new panel. I've started cleaning up the flanges and removed the radiator support from the old valance. With the nose of the car open I've a got a good opportunity to clean and paint too.

Anyone else done this job? I'd like to know any Musts or Donts before I get too far.

Thanks!

[Richard B]

Found I needed to get my head through one of the grill holes, so that I could see to weld the lower seams with a Mig.

Alternatively if the shell was high enough off the ground you could stand in the engine bay to do it.  :-/

[Vitesse2l]

Thanks Richard...So first job is to shrink my head, then?

Access is tight for the wing/valance flanges. The previous repairs on my car were brazed from the outside. The flanges seemed spot welded properly too - I certainly had the expected amount of work removing them.

Engine is still in, so it'll be the contortion approach, I think! Wonder if a mirror might help.

[Richard B]

The top and bottom flanges are fine, its just the joins with the wings.

If you use the plug method with a MIG, drill holes in those flanges of the valance before fitting (seems obvious but easily forgotten)  :B

[Vitesse2l]

Forgetting those holes would be a doh! moment. I'm perfectly capable of that sort of thing.

I spent some time today wire brushing the headlamp panel and finding more holes to patch. As with the valance, nothing too big, but more than I wanted. I'll be a few days making small repair sections and butt welding them in.

I'm not going to replace the nose of the car so it'll get a 'good enough' job for the moment. It's not going to spend much time in the rain, so hopefully with enough attention to paint and waxoyl it'll be good for several years. Half the problem with a job like this is knowing when to stop! I'm certainly deeper in than I anticipated, and I started with what I thought was the worst part (rear lower wing and wheelarch).

[Vitesse2l]

New panel arrived today.

Why do these always seem more flimsy than the old rotten bits you took off?

I suspect it's just the difference in weight due to paint and underseal.

A bit more adjustment to the car and I can see if it's anywhere near fitting.

[mikew]

Vitesse2l wrote:

New panel arrived today.

Why do these always seem more flimsy than the old rotten bits you took off?.

A lot of the re-pressed panels are in thinner gauge metal than original, they flex more too as a result.

mike

[Richard B]

Quote:

are in thinner gauge metal than original

Easier to press with the low power presses used today.

OE was done with a 100 ton press and took ages to change the dies over. Hence the long stockpiles of panels the manufacturers had to keep.

[Ridgetone Triumph]

Vitesse2l wrote:

Why do these always seem more flimsy than the old rotten bits you took off?

.

Maybe they were part of the stock that was sent to New Zealand so the company could double up on stock?