What Have You Done to Your Cougar Today?

Holy **** , I dont think you could call that a sill there isnt enough left.

That passenger side looks good ,keep fighting the good fight :) your doing great work my friend keeping her going when by the looks of it anybody else probally would have sent her to the race track in the sky
 
There are some very talented people out there. That looks brilliant. Back in the day, it would be a gob full of filler and a quick spray job, Thank goodness those days are long gone
 
I used to attach perforated zinc sheet with pop rivets, cut it to shape and do the same on the inside, riveting the two. A coat of P40 sealed the holes and then a skim of P38 over the top. Still not kosher by today's standards, but manageable for a bodger like me...
 
Cheers for the nice comments guys, seems crazy but I love doing stuff like this, (when time and other factors allow me to) the body work is starting to "go" in certain places, rear arches, front of bonnet etc, and this is one thing that scares me as I have no clue as to how to prep/repair/paint, but as long as I can keep her structually sound I can sort the body work/paint some how, even if I have to pay people to do it..(y)
 
**** me O'Reilly. Thats even worse that mine was when it came out of the garden. Apart form that passenger side bit mate, good as new, you should be pleased with yourself. A bit more of that and a dollop of rustproofer and it'll be all set.(y)
 
Throttle Position Sensors

Old-ford-fran said:
...Just checked my spares bin and I have 2 with the code: F5RF 9B989...
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Good news Paul ! Both of those Throttle Position Sensors check out well physically and electrically. There is one parameter that can easily be missed and that is 'noise', but I've checked them very carefully and don't think that's as issue either.

So there is a spare if you would like it and I need to settle up with you for the other one.

Thanks again - Noel
 
Foobar said:
Like Chris, I am absolutely gobsmacked with what you are taking on there Paul. I'm getting all enthused now and will probably look out my MIG welder this weekend. I think the wire is still in the airing cupboard somewhere, where it must have been for 20 years !

What are you going to do 'on the inside' to keep the rust at bay ?
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I'm using Kurust for the rust prevention.
 
Also Paul, what grade of sheet metal are you using ? Despite the issues with burning zinc, it seems a lot of people use galvanised steel, but what thickess is ideal for this work ? I guess its a balance between ease of shaping the metal and strength of the replacement. I have a lot of panels from computers, not the cheap foreign desktop variety, but lids and sides off servers that look and feel 'heavy', can I hack those up ? They will no doubt be electroplated zinc, rather than hot dipped with visible crystals, but would it be any good ? I can always measure thicknesses first. Any guidance would be appreciated... TIA
 
dandamano said:
Ive been using this on both the Cougar and Focus, works well and its a lot cheaper than Kurust

https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/273169781875
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Bought. Prime delivery tomorrow.

By the way, if you're getting deliveries of any sort through whatever company, when they rock up please offer them a glass of water right now. They might be carrying their own (as ours was) and that's fine, but don't let any worker have to get dehydrated for no damned reason.

You don't have to invite them in, but you can offer them a glass and you should.
 
Noel, I use one of these to get the correct gauge/thickness of any metal I am looking to repair/weld.

​
https://www.ebay.co.uk/itm/Steel-Ro...l/112597054910?ssPageName=STRK:MEBIDX:IT&_trk

I have never used galvanised steel personally, if you use the above tool, you can get the correct spec metal, I have various size thickness sheets in my spares bin from older/previous projects I have done, just try and get as close to the original spec as you can, if it is slightly thicker it's not too difficult to shape as I find the heat helps when you are weding it.

Thats how I do it anyway, not sure how other's may do it, I am only a hobby type welder, I have no qualifications, just learned by trying to do it myself and save some money...(y)
 
Chris - Did you see how much 'Stormzy' was sweating last night at Glastonbury ? At one point he looked like he might expire from dehydration before the end of the song...
 
Foobar said:
Also Paul, what grade of sheet metal are you using ? Despite the issues with burning zinc, it seems a lot of people use galvanised steel, but what thickess is ideal for this work
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You need Tony or Paul here. I absolutely cannot comment on Tiger's rear wings, chassis rail, rocker covers or floorpan. They saved her and I trust them, but have no idea what exactly was used.

I suspect that we're looking at 2 to 3 MM though depending on where, except for the structural things.

u4nwqt0.jpg
 
Thanks Paul. I love gadgets and that has got to be in my toolkit. I'm also planning on getting one of those 'automatic' welding helmets from Lidl. I've never been able to use the old fashioned fixed glass versions. I used to end up striking the arc and then pulling the mask down, by which time I had either moved or not moved and lost the arc or stuck the torch to the car ! I think they were £25 when last on sale.

https://www.bricovideo.ovh/video/pr...helmet-lidl-psh-3-accessories-test-manual.php

lidl-parkside-automatic-psh-3-test-avis-notice.jpg

That reminds me of a true story some 35 years ago when we lived in Lowestoft in quite a nice semi. One night there was crashing about and screams from next door. It sounded terrible, like somebody was being murdered. However, we knew the neighbour was at home and was a police sergeant. It turned out his son had been learning to weld and thought it clever to do away with the helmet. He had 'arc eye' and had woken up in agony and completely blind. It took several days for his sight to return completely and I suspect he didn't do it again.

I think I just need to get started and I will simply progress around the car. Which reminds me I need to post my own pics of what needs welding on KGV and a copy of the MOT failure...
 
Old-ford-fran said:
Only just noticed this Noel, glad they arrived ok, let us know how you get on with them...(y)

- - - Updated - - -

Started the mot repair work today on my Ebony C1 (I need a name for the old girl...) she has been stood for a few months due to various personal issue's, but hopefully now I can get back on track and get her tested and looking her best again, then it's on to sort out my recent C2 purchase from Mike.

Anyway here's some piccies from today's jobs...

Got her up on axle stands and wheels off to have a good look around.

View attachment 13293

Here's a "not pretty" picture... big hole at the front passenger side sill...:eek:

View attachment 13294

from a different angle...

View attachment 13295

And we all know what this is, don't we.....found this in the rear end passenger side, safe to say it has now been well and truly discarded.. expecting the same on the other side, but there's enough here for now to keep me busy for a while...

View attachment 13296
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Nothing to worry about sir, they all do that. Ahem.
 
All ordered. I notice I can't beat your prices either ! Thanks for the help.

I spotted these magnets and thought 'something fishy here'. They are clearly extrusions and I don't think you can do that with steel ! Crafty lot these eBay sellers...

aluminium magnets.jpg

I have a set of 'blue suede gauntlets', lets hope nobody steps on them - lol
 
Noel, I don't understand - I'm literally ignorant here - what you mean about the magnets.

I mean I can see that they have limited utility and a very specific use, but are they totally useless or something?
 
Sorry Chris, I didn't really explain properly. The metal frame the magnet is sitting on at the very least looks like aluminium extrusions to me. The shape of the right hand piece has a deep internal groove and the little external grooves visible on the other pieces all tell me 'extrusions', which in an everyday world can only be aluminium. Therefore the magnetic clamp has simply been 'posed' on this frame, a puff of wind would blow it off unless it were sitting on iron / steel. Even the direction of the top screw goes against it working on potentially steel screws inside the aluminium frame, in a word the photo is a 'con'. I'm sure the magnet is fine though and have ordered the other set as recommended by Paul...
 
The set of magnets I put up are a good tool to use for practicing your welding, they will hold pieces of box section in place to practice your weld technique, also depending on what/where you are welding on a car, they can be of use too.
 
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