Regular blog readers may remember Kerry's handiwork in the welding of the new strut-towers (see the blog post here http://boogermobile.blogspot.com/2011/04/front-suspension-cross-brace.html if you need a refresher!)
First task, of course, was to clear the remaining area of the shed so that Kerry had plenty of room to work in... Here's the before shot...
And through the magic of the interwebs, it's all finished!!
And looking from the shed door... you can see there's plenty of room beside the passenger side now!!
Jason and Kerry arrived, and Jason brought with him Booger Mobile's fully rebuilt and reconditioned starter motor... it has the original casing, but just about everything else is brand spanking new. The boys are loving the work of Pine Rivers Auto Electrics!!
Time to get to work... first step was to put the car up on jack stands and check out the damage and alignment of the control arms...
In order to make a reasonable comparison, the driver's side was removed also, so that Kerry could check it out and do some measuring...
Damian's next job was to remove all those pesty wires that were likely to catch fire if left in the way of where Kerry was going to be welding...
That looks safer!!
Kerry (right of picture) and Jason use the knockometer to check out and adjust the alignment of the existing bracket...
Time to get out the gas-axe and adjust the shape of the flat steel plate to make it a perfect fit...
Getting hotter...
And an action shot of hammering the plate...
Kerry is rightly impressed with how the plate fits the required shape!!
Jason helpfully decided to tie the extractors up out of the way - using the header wrapping tape, much to Damian's angst!
Kerry checks out the fit of the plate, while Jason points randomly to the next bit that needs adjusting!
And what metal-working blog post would be complete without some angle grinding... It all seems so much easier with the flash new bench to work on!!
Kerry decided to see which angle would be best to weld from... turns out it's a tight squeeze!!
Instead of lying under the car, he decided sitting in the engine bay was the way to go... As you can see, there's so much more room!!
Welding up the existing bracket...
Yep, looks good!!
Bit more angle grinding...
Kezza, keep your head out of the way of that gas-axe!!
What could possibly go wrong???
With the bracket in place and partially welded, it was time to bend it further into shape...
Safety first!! Damian improvises some eye-protection for while Kerry's welding!!
And the first plate is in place!! Still a bit more welding to be done, but the shape is right!!
Kerry had a well-earned break from being wedged in the engine bay, and spent the time hammering the next plate into shape!!
More gas-axe...
Check out the heat in that plate!!
And it's beaten into submission, but still red-hot!!
Kerry gives it a little drink to cool it down...
Jason attends to the trimming of the second plate...
Then Kerry is back in the engine bay, welding like a big welding thing!!
And the sparks fly as Kerry tidies up his handiwork...
Time to load another stick...
And more sparks!! Kerry is a bit of a perfectionist, which isn't a bad thing!!
With the welding all completed, the paint has burned off into the shape of the Aqualogical logo!! Doug will be pleased!!
Jason grabbed the camera and took another shot to plug his business... Nice work, Jason!!
Time to put a protective coating on the welded portion... Damian will get some touch up paint during the week and respray the engine bay where required before the engine goes back in!!
And the sub-frame has now been strengthened!! Massive thanks go to Kerry for his time and expertise - one important job has been completed as Team Booger Mobile heads towards the 2011 Camp Quality esCarpade!!
HOT HOT HOT REAL HOT STUFF
ReplyDeleteAnother day closer to the Camp Quality finds Damian working hard to finish cleaning the last bit of the Booger Mobile HQ.So that Jason's friend Kerry ,will have room to move around and under the Booger Mobile while he does the repair on the subframe.
Just looking at all the great pictures shows everyone what a fantastic job Damian did cleaning up, and also showing the master of welding, Kerry working ever so hard to repair the subframe. Just look at that finish,its AWESOME.
Here's hoping thats the last time we see anything other than the Booger Mobile engine, in the engine bay.(can 't wait to once again hear the Booger Mobile roar into life,and purr like a kitten how sweet will that sound be.
Well that was one long hard day for the guys,but a lot was achived, well done thank you Damian, Jason and not forgetting the master of welding Kerry.
PS
The recon of the starter came up a treat.