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Re: Ed's 81 Datsun 1200 ute build
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Hey Harrison, yeah nice bike .. I'm far from a factory rider tho.. lol

Some more progress... not much but each win is a win. Reinforced the inner sill before welding on the outer and shaping up the ends for the overlapping panels. If I knew then what I know now, I would have bought better quality outer sills with the shaped ends.

inner sill structure
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outer sill done..
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Next to smooth out the hook notches in the tub rail, fit the tail light corner and rear quarter.

Cheers Ed

Posted on: 2011/4/4 23:03
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Re: Ed's 81 Datsun 1200 ute build
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Update time. it's been a while.

latest completed jobs are installed the rear quarter and sill, smoothed the rail and fabbed up a new floor pan for the passenger side.

I opened up the rear quarter on the drivers side and as expected the lower sill area is cactus. looks like I will need to make up a new inner sill as well...

the new rear quarter
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smoothed rail
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new sill and floor pan
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another shot of the floor pan
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now for the ugly...
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Cheers
Ed

Posted on: 2011/4/27 22:59
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Re: Ed's 81 Datsun 1200 ute build
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Hey Ed, more good fab work there.
I'm currently feeling your pain with the inner sills. It's not till you get the floor out that you realise that they're now made of swiss cheese!
I'm just getting some sheet metal folded at the moment to match the step down to where the inner and outer sills meet. A sheet folder would be a bloody handy tool to have!
Keep up the great work! You're giving me hope!

Posted on: 2011/4/28 0:41
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Re: Ed's 81 Datsun 1200 ute build
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Hey Shoota,

I've been enjoying your updates and at this point we are both having to attack the same area.

I have a bead roller that can flange the panel for me, and also run beads as seen on the floor panel.

I made a bender that can do up to about 500mm wide, anything above that I just clamp the sheet between some metal tube with G clamps and bend it over with a dead blow hammer... not fancy but it works.

My plan of attack for this side I think I will repair the inner from the inside out, then as per the other side. I will keep the remainder of the floor in place to brace the shell in the mean time. as you mentioned in your thread, there is not much holding these things rigid if you start cutting.


Another difficulty with these jobs is having a good reference point to measure back to. I am keeping the door in so I can watch gaps and have something to run my eye against.

all fun and games.

Cheers

Ed

Posted on: 2011/4/28 0:55
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Re: Ed's 81 Datsun 1200 ute build
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I just went and purchased a high tech sheet metal folder at Bunnings this morning, two bits of 4 by 2! Just gotta screw them together with a 2mm gap and we're good to go!

Posted on: 2011/4/28 2:16
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Re: Ed's 81 Datsun 1200 ute build
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cheap and cheerful!

just sandwich your sheet between it and bend away.

I normally use wood for simple hammer forms, the edge can lose it's sharpness so sometimes you can get a wider radius bend..

here's a pic of simple bender I made up from scrap and cheap hardware items. You clamp your sheet down and pull up to bend.. it places a bit of stress on the hinges but ok.

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Open in new window


Cheers

Ed

Posted on: 2011/4/28 3:11
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Re: Ed's 81 Datsun 1200 ute build
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That's awesome, I'm gunna make one of those, would make it heaps easier!
Thanks for that.

Posted on: 2011/4/28 3:29
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Re: Ed's 81 Datsun 1200 ute build
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great build so far mate, love the fab work keep it up!
that bender is a great idea mate have to jig one up.

Posted on: 2011/4/28 12:48
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Re: Ed's 81 Datsun 1200 ute build
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thanks, yeah the bender is handy, it can do up to 1.0mm zinc anneal. I should have used beefier hinges but that what 2.60 buys at bunnings

works well... you get nice sharp folds, certainly better than trying to use a vice etc.

having said that, the sections I made up for sill reinforcements pictured earlier were just folded up using bits of metal and g clamps and the dead blow hammer... use whatever works!!

I should have my drivers side inner sill done this weekend, cut all the old crap out last night and measured up for the new panel.

Cheers

Ed

Posted on: 2011/4/28 23:01
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Re: Ed's 81 Datsun 1200 ute build
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Another update.

drivers side inner sill, bracing and outer was cactus. I have fabbed up the inners and bracing and now tacked the outer sill back on. The floor pan still needs to be replaced.

here are some pics of progress.

inner sill rusty.
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cutting out all the rusty bits.
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fabbed up an inner sill
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inner sill from the inside
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inner sill and rear wheel arch repair
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inner sill bracing.. ready for outer sill which I have tacked in but no pic yet.
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Hope this is helpful to others who are doing the same jobs with rust.

I have certainly been enjoying reading other's threads, just need more time to read them all!

Cheers

Ed

Posted on: 2011/5/9 0:56
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