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Thread: "How to" plate rotten top plates (Daves way)

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    "How to" plate rotten top plates (Daves way)

    An old thread that I thought would be useful in here

    Often the strut tops have been plated over in the past, usually straight over the top of rot and without any paint

    This is the top plate on Fred's car before I tackled it. Looks very good, and it was, but from underneath you could see the rot.



    Ground out the welds and took the repair panel off. Here you can see what was underneath. Typical really, plate straight over the old rot and no paint or treatment whatsoever.



    A chunk of the top skin carefully ground out to see the strut top cup, which is usually rotten too.



    Once some of the top is cut out you can see how much to take out, lining up the replacement panel as a guide. The replacement panel can be seen in the pic above, a Hadrian panel.



    You can see the cup is removed as well, along with the top of the uprights. The replacement cup normally comes with the uprights too. In this case I decided the uprights were still useable. I don't like cutting out the original stuff if it's still OK. I have done the whole uprights before though.



    These bigger repair panels tuck just under the bulkhead lip and meet up with the top of a swage at the front end. They can be made to fit very neatly.



    Top plate tacked in place. Take lots of measurements before taking anything off, to give you an idea where it has to go back. I find that the replacement panels tell you where it has to go.



    New cup in place



    Plug welds holding strut top and cup together.



    Fully welded in and all primer removed.



    Etch primed



    With a little bit of skilful grinding and a smear of filler it can be made to look original. Don't forget a good coating of paint and underseal underneath. Zinc primer between panels before welding. All helps prevent having to do it again.

    Hope some of this helps someone attempting this, it is a daunting task if you've never done it before. My biggest worry was how I was going to get the new one in the right place. To be honest as long as you compare the new panel to the old before cutting anything it all becomes obvious as you go. I don't claim to be a pro at the job by any means, but that's how I did mine and I'm happy with it
    Last edited by Dave; 14-06-2008 at 20:14.

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    Re: "How to" plate rotten top plates (Daves way)

    Tip! If you got a bolt on strut brace lying around, use that to set the position as well for extra reassurance. HTH
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    Re: "How to" plate rotten top plates (Daves way)

    looked quite usefull that mate, how much are the panels?

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    Re: "How to" plate rotten top plates (Daves way)

    I am just about to replace the top plate on my Mk1 would it be advisable to put strengthening plates on top of the the new plates or would its be strong enough with the standard top plates

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    Re: "How to" plate rotten top plates (Daves way)

    Depends what you will use the car for, but I have never bothered.
    Rallying or racing will need them.

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    Re: "How to" plate rotten top plates (Daves way)

    Could you do it with the outer wing on?

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    Re: "How to" plate rotten top plates (Daves way)

    Is that a challenge?


    Probably if I was desperate. I would have to be pretty desperate though.

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    Re: "How to" plate rotten top plates (Daves way)

    There's just a wee bit of rust coming in around one of my struts, and I was wondering if it's going to be a big job like this to sort.

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    Re: "How to" plate rotten top plates (Daves way)

    If it is a tiny bit you can cut it out and patch the hole. What you usually find is that there are about 3 layers of previous plates in there and the whole lot needs doing.

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    Re: "How to" plate rotten top plates (Daves way)

    nice 'how to' dave

    of course not all of the above apply exactly if the strut tops have been bodged beyond belief in the past

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    Re: "How to" plate rotten top plates (Daves way)

    i'd just like to now add, i didn't find this nowhere near as difficult or awkward as i was expecting it to be.

    i was dreading having to do the struts tops & cups but i reckon a front floorpan is more aggro



    i just done mine slightly different. very briefly..... i cut the top plate out then got the new one in place & tacked it all around the edges. this then had the strut repair directly over the original cup & dead centre. i'd already sliced the verticals down as far as i wanted them on the inner wing so then it was a case of cutting through the uprights horizontally to remove them & the cup as one. i then cut what i needed from the new verticals. clamped the new cup directly under the new strut repair & plugged it then fitted the top sections of the uprights. obviously all treated & painted as dave said.

    page 11 - http://www.turbosport.co.uk/showthre...32#post1704832

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