S-Ltd - "The Black Lemon"

[Lumphammer]

I imagine the repair / strengthening frame rails go over the cut out originals, get plug welded to the existing floor and the strengthening plates are plug welded on the inside of the car. The floor is extremely thin so structurally the plates "close up" the box.

If you look here where I repair my frame rails I think it'll make more sense. My replacement frame rails go under the end pieces like the originals, these I think go over the end pieces

viewtopic.php?f=35&t=7585&start=15

3mm will be extremely strong. From memory the originals are 0.7mm

As for the floor to sill panels they aren't trivial to fit and I've not worked out how to do it myself yet. I think the middle floor to sill section gets cut out first giving access to the two ends which are then cut out, replaced and the middle part then replaced on top. Access is from cutting the bottom few inches out of the inner sill. I think, I'm not 100% sure..

I'm using a two part zinc silicate weld through primer (the red stuff) if it doesn't need welding through I'm using a 93% zinc epoxy. Both products are from rust.co.uk - I can't say if they're any good or not because it's the first time I've used them. The frost or upol weld through in a spray can is vastly more convenient, having to mix it up is a pita

[Mazda Mender]

Steve from Pro bodyworkz will be popping in to help with directions chaps, Tom as already been in contact with Ste, best fabrication guy in the UK with the cars.
M-m

[drumtochty]

The floor rail strentheners have a video on the Lightsuplights down channel where Roy welded some on to his Mk1 with the prototype set of rails. I'm just in for lunch as we are chain sawing a number of trees off someones roof up here in Aberdeenshire. That is firsts priority as the lady lives there on her own and is a bit afaid to say the least.

It has been windy here where we have lived for 46 years and there are just loads of tree down.

Will try to dind the video this evening and post the link

[graymattor]

Thanks drumtochty, i was skimming through their videos but not found anything as yet, but Ollie at MX5 Restorer has sent me the below, he has been very helpful..

Quote
I have attached some photos of the process to give you an idea. This is in a MK1, so will differ slightly if you have a mk2 but its very similar. You can either just spot weld it in the original holes which are drilled out, or you can do that as well as seam weld them too if you would prefer that. They will need seam sealer either way and also zinc priming on both sides to prevent corrosion too. Let me know if you need any more help.

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end Quote

I bet these photos are from the MK1 you mentioned, i will keep looking to see if i can find the video but these have helped a lot, i can visualise exactly what needs doing and they look pretty damn good when fitted, should and plenty of strength

Keep up the good work, it sounds like the weather is giving you quite the battering at the moment

[drumtochty]

Sorry for coming back late with the link but I found the clip of the installation of the prototype replacement rails to Roy's own Mk1.

https://www.youtube.com/watch?v=lsFqJVKGZns

[drumtochty]

This is the reason for being away for a few days.

Lucky that the tree was an evergreen as it was cushioned as it hit the roof only a couple of ridge tiles cracked .

We spen three days to remove it in small pieces and in a safe manner.

It was not me on the roof.

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[blackyb]

A bit of windblown timber, I remember tackling it years ago as a whipper snapper forester.

Pleased you clarified that it wasnt you on the roof and that in fact they were on a roof as at first glance I thought otherwise.

Waiting for the next installment in "The Black Lemon"

[Mazda Mender]

Are you branching out into another thread or am I barking up the wrong tree ..
Sorry I'll leaf it alone.
I'll get my coat.
M-m

[graymattor]

Sorry to disappoint but no real update this weekend.

Im trying to balance house renovation with the unexpected MX5 surgery, time is not on my side!!

All i managed to do was:
- Paint up the calipers, these are ready for a full rebuild now
- removed the passenger door, take the seat out and generally tidy up, so i now have two doors in my garage roof, a full ready subframe (and the rest of the car) in the attic - how can such a small car have so many parts!!
- i went to do some more grinding but cant find my grinder D nut ffs! so that stopped that! so i fitted the angry wire wheel of death and went to remove some underseal to see how the floor looked and well its rusty on the inside as seen in previous posts but the outside isn't bad, the front drivers jacking point doesn't look bad at all, so i am not sure whether to treat it or replace it! the rear is absolutely shot! removing underseal laid on your back is bloody hard work, ill have arms like Arnie by the time i'm done!!!
- i have started making my door braces, they will be the same as Lumphammers but ill be using pipe instead of box but without a grinder i couldn't make these.
- i fired up the welder, fitted the 0.6mm wire and its working lovely, can get a nice weld so spot welding wont be an issue, what white are you guys using, is 0.6mm sufficient? i also got no juddering on the wire feed, but i am using a 5kg reel, may the 25kg of 0.8 i was using was a bit heavy and it wasn't rotating smoothly, i'm not sure, unless i didn't get it located on the spigot right (just thought of that now so i didn't check) and it was rotating on one of the slots which would make sense

It looks like i have some work to do on the main drivers floor, it looks as though some daft person has tried jacking on teh floor, its bent in and looks awful! no idea how ill straighten it out but i wont be leaving it like that!

Sorry no photos, we have been without the internet since the 25th Jan so i have to leave my phone in the house as a hotspot!

[graymattor]

Sorry for coming back late with the link but I found the clip of the installation of the prototype replacement rails to Roy's own Mk1.

https://www.youtube.com/watch?v=lsFqJVKGZns

Thanks for the link drumtochty, i hope you managed to clear everything safely and OK

[graymattor]

Trying to plod on, but the more I do, the more holes I find, im really struggling, I'm out my depth with all this to be honest.. cutting things out is easy, putting back in is a nightmare! And that's the replacement panels, I need to some how make the rear inner sill section and replace jacking points some how!!

I think I'm a lot overwhelmed!! There is rust everywhere I look!!!

I want to do it but at the same time I just want to conceded and give in, sell all the parts I have and buy something I can enjoy car or bike (want to do my bike licence)

Just not sure, scared of doing all this and ending up unhappy with the results!

I'

[Mazda Mender]

Look there is no rush, take your time , no master pieces were done over night...I have five builds on the go.. personally...3 need to be finished for summer for sale and the others are mine for me which are taking a backe burner to be finished this year..I am also looking for a white MK1 to restore for the daughter and a 1.8 project MK1 for a build in my head I want to see in the flesh...
It all takes time.
See this as a kick up the ar*e to motivate, finish stripping , make a plan ,you have achieved the hardest bit of strating, that gates open now to start climbing that hill, rebuilding is the trip back down...you can do it....make a good solid list to work through.
M-m

[blackyb]

Your skill levels already way above mine.

The work you have done so far shows determination to find a work around and the results have been impressive.

Seems a shame to throw in the towel but I get how you feel, one step forward three steps back.

Take a bit of time out, go get that bike licence so you have achieved a goal, then get back in the boiler suit and tackle the rest with a clear head and a bike that you can jump on to ease the stress.

I used to have really crap days at work, but the ride home on the bike after a shift was better than anything anyone could have prescribed.

[graymattor]

Look there is no rush, take your time , no master pieces were done over night...I have five builds on the go.. personally...3 need to be finished for summer for sale and the others are mine for me which are taking a backe burner to be finished this year..I am also looking for a white MK1 to restore for the daughter and a 1.8 project MK1 for a build in my head I want to see in the flesh...
It all takes time.
See this as a kick up the ar*e to motivate, finish stripping , make a plan ,you have achieved the hardest bit of strating, that gates open now to start climbing that hill, rebuilding is the trip back down...you can do it....make a good solid list to work through.
M-m

Thanks M-M, I can handle some projects but this is getting way out of hand now!! I've had the car 5 years now, bought it at a high price because it was from a collector who I trusted, ive driven it 10 miles and it was awful due to the front suspension leg being bent, I started the project at that point, I've easily put £3000 if not more in to it, (some I haven't got yet like custom seats and interior) and all the car wants to do is die and go to the scrap yard, no matter what I try and do I just bloody make things worse, after all these years I'm ready for giving up and getting it out my life, it's always there reminding me of the mistake in buying it and the mistake in me thinking I can sort this out!!!! Im having sh*t at work, then spend all weekend getting no where and getting sh*t from the bloody car!! Yes I want to do it, but more from the fact I want something nice that I can enjoy, its just not a hobby or fun its gone past that, I'd happily cut this bit in between out!!!!

Your skill levels already way above mine.

The work you have done so far shows determination to find a work around and the results have been impressive.

Seems a shame to throw in the towel but I get how you feel, one step forward three steps back.

Take a bit of time out, go get that bike licence so you have achieved a goal, then get back in the boiler suit and tackle the rest with a clear head and a bike that you can jump on to ease the stress.

I used to have really crap days at work, but the ride home on the bike after a shift was better than anything anyone could have prescribed.

Thanks BlackyB, unfortunately it doesn't feel or look that was from my perspective!
Yes very much, one step forward and three back, but more like none forward and 5 back every day I'm on it!
I started the road to my motorcycle licence late last year, CBT and Theory done, just waiting for better weather to start lessons , I do have a Cagiva Raptor 125 project (everything is a project because I can't afford good and decent! House bike, cars ) bikes are definitely easier to work on, etc than cars! So will see, this car has taken a chunk of the savings I was using for lessons, but im not doing anything bike wise until its better weather so a bit of time yet

Honestly after seeing the mistake in the garage for 5 years, I dont know how much more time I really want to give it! I feel like all these years it's just sucking any interest or enthusiasm right out of me! Almost as though it doesn't want me touching it and wants to rot in peace!!

[graymattor]

Well may as well throw some pics up!!!

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