Jim's MGA Restoration
Progress of my restoration of a 1959 MGA Roadster
Tuesday, January 03, 2012
Monday, September 26, 2005
Progress Stalled - September 26, 2005
Tuesday, September 20, 2005
Progress - September 19, 2005
September 19, 2005
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Gasp! Not much progress this week due to press of other duties. I did receive my three carbide burrs and tried one out using a portable drill instead of the angle die-grinder. It seems to cut pretty well, and I'm hopeful that I can shape the welds up fairly easily. Also the company will re-sharpen the burrs for 40% of the new cost - that seems like a deal to me.
I tried to buy a replacement transmission tunnel, but fooled around and missed it on ebay; however, at $100 plus about $20 shipping, the cost was high enough to justify repairing mine.
I also bought some steel and made sketches of the replacement battery trays. From the chassis drawing on the "mgaguru" website, I scaled these to be 7-1/2" wide if anyone wants to know. So I have plans to build them, but then yesterday I was looking at Todd Clarke's catalog, and he sells the battery trays for $95 the pair. Seems like a good price, and a better solution, so I may buy from him, although they would be for 6V batteries, and I would still have to extend one to go to a single 12V.
I also bought anither 4-1/2 grinder - this one a Ryobi for $39.95 from Home Depot - so maybe it'll last longer.
Other than that, it was a slow week on the MGA, but I'm hoping for good progress on my Friday off this week.
Monday, September 12, 2005
Progress - September 12, 2005
============================================================================= The pressure, the pressure! Must make progress to satisfy the blog monster.....
Tuesday, September 06, 2005
Progress - September 5, 2005
September 5, 2005
Now I am getting into the mode where I feel obligated to make some progress each week so I will have something to post to the blog. By the way, the cheapo $7.99 grinder worked pretty good for five minutes, then stripped the gears and now won't do a thing. Hey, it was worth (?) a shot!
Passenger side. It will be nice when this stuff is all one color!
Monday, August 29, 2005
Progress - August 29, 2005
I decided to go back to the flux core weld wire for the frame work, as I need to have 3 fans blowing in the 96-degree Texas heat to keep things bearable, and the gas mig doesn't like wind a lot. Also, for some reason, Welding Depot sent me a regulator that only goes down to 5 cfh, but the Clarke instruction manual says to set gas flow to 2 - 4 cfh. Consequently, I think I am using too much gas, even with the knob adjusted to the minimum (or below). I think my cheap helmet is making it hard to see the weld bead, so I may have to upgrade soon.
Here is a picture of the fixture I used to lift the body tub off the chassis. With the engine hoist and this bit, it was an easy one-man operation. When I reinstall the painted tub, I will pad the curved end pieces.
I made fairly good progress on installing the floorboard rails in the cockpit area. They are a little bit complicated in the rear corners because of the wedge piece that hangs below the frame to catch the rear of the rails. There is some cutting and fitting necessary to work around the upper part of the spring hanger, keep the bottom edge level, tie in to the lower spring hanger, etc. I botched the fit-up a little on the driver's side, so the wedge piece wasn't flush to the frame underneath, but cut the welds loose and "adjusted it with a hammer.
Here is a view showing the bad fit-up that I was left with - see the gaps? I had to cut little slivers and weld them in to take care of this - just tedious slow work on a hot day. Blah.
The passenger side was better, although the welding was not pretty. In this shot you can see the triangle wedge piece "welded" in. I spent a few minutes on Saturday sandblasting the attachment points for the floor rails in order to have clean metal to weld to, but boy is it messy and irritating!
Notice the rusted section at the corner of the center support rail. I cut this out with the air cutoff tool, and welded in a replacement. Welding in short 1/4" beads works best. This type of repair is actually pretty fun to do. After grinding it will be invisible. Speaking of grinding, I bought a new 4-1/2" angle grinder off ebay for $7.99, including sanding/cutting discs! So now I won't constantly have to change wheels on my one grinder - what a deal! I still need to buy an angle die grinder though to get in the corners to clean them up.
Finally, here are the rear rails welded in. Alignment and fitup was a bit tricky, and it would have helped to look at another MGA; however, my book helped some. I need to fabricate the dogleg support pieces that go up and around the spring hanger, as Todd Clarke doesn't show them in his catalog, and Moss wants almost $30 apiece for them. I should be able to make them in 16GA pretty easily. To get the rails properly alighed, I set the frame level, then leveled the side rails off the center rails and worked around.
Friday, August 19, 2005
Progress - August 22, 2005
August 22, 2005
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This past week I finished up the welding and grinding on the main frame rails. I ordered and received an 11lb. spool of Spoolarc "Easy Grind" bare mig wire - .030 size. Also got my gas bottle filled with 75/25 Argon/CO2 mix. This is a small 20lb bottle, so we'll see how long it lasts. Couple of lessons on the gas bottle - it must have a sticker on it identifying the contents (for HAZMAT clean-up, etc.), and the welding supply place will apply it if needed. Also, pay attention to the manufacturing date stamped on the bottle. Mine has a 10-year life, and must be recertified after that, at $25 cost. Some stores exchange bottles, and if they give you an older one near its expiration date, you may have trouble the next time you go for a refill; better to keep your own.
Progress - August 15, 2005
August 15, 2005
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I didn't actually work on the MGA on the 15th as it was my 35th wedding anniversary! My long and happy marriage is due to by tolerant and bemused wife, Michael Ann.
This past weekend, I continued work on the main frame rails, welding and grinding. The grinding goes fairly quickly using a 4" dia, 80-grit flapper wheel on my angle grinder; however, it takes some finesse to get things smooth without taking off too much base metal. I will put a thin coat of bondo over these welds before painting the frame, so they will be almost invisible.
This picture shows the end of the square crossmember with a rusty section cut out. Also visible is the replacement section of 16GA steel. The new piece was cut out with a saber saw and a metal cutting blade. I emptied about a half cup of junk out of the end of the crossmember before welding this back up.
This picture shows the welding in progress. I am using .040 flux core wire, and welding in the vertical position. As long as you work with short beads of about 3/8" and skip around, things go pretty smoothly.
This shows the weld finished and ground down. This was a quick and easy repair - very satisfying. I think I am also going to have to do the other crossmember end, as well.
Recap of Progress through August 8, 2005
=========================================================================== June 20, 2005
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July 25, 2005
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August 8, 2005
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