Inner Wing - One For The Smart People

[MK1_Oz]

My passenger side inner wing is in a terrible state...




so I bought a front quarter cut from a donor car to replace it with...




Has anybody got any clever ideas as to how I can cut off the old wing to match the cut of the replacement one????

My idea was to measure the length of the replacement chassis rail then cut the old one off to the correct length (the various holes in the chassis rails will work as datum points to get this cut pretty accurate). I was them going to hold the replacement panel against whats left of the old one to mark where to cut. Will proceed with this unless there is a better solution to be had!!!!!

[exboyracer]

Cut off as much as you want to replace on your existing wing, then offer up the new panel against your existing wing, match up the vertical channel on both wings and draw around the cut.

You might have to cut off your existing front chassis section to enable better positioning.

[MK1_Oz]

Cheers ex. Very similar to what I was thinking although all done on the bench rather than the car....sounds easier.

[oddy]

This is how I would do it,
Chassis leg.
Firstly, on the donor panel drill out the spot welds between chassis leg and inner wing and seperate the two panels.
Mark the new chassis leg and cut the section you want to keep, take a 3 sided cardboard template (top, side and bottom) of the bit you want to use, transfer this to the old leg, cut and weld.
Inner wing.
On the original inner wing cut most of the excess off, but still leaving about 20mm of overlap, then place the new section of inner wing over the top, because you have already attached the new piece of chassis leg you can line the two panels up perfectly due to the spot weld holes you drilled out earlier, mark the new panel against the old, cut the excess off and weld away!
Hope that all makes sense, i do have a inner wing at the workshop that i have done pretty much the same on if you want some pics to make it clearer, cheers
James

[Darbo]

you could always bolt some good angle iron through the crossmember holes extending forward and up along side the bumper bar bracket tubes so you can insert a bolt through the 2 tubes
basically making a chassi leg end jig

that way wen you cut off you know is going back in the same place

[jpblue]

OZ,

I think separating the newer parts is the best way also allows you to treat and finish inside the rail before reassembly. After carefull measuring, cut away the crap original such that only good metal is left, offer up the new chassis rail, after removing it from the panel and using measurements taken from the original and the available tech drawings replace the section of the rail tacking to start with. then as described above use the original spot welds to align the newer panel, scribe it against the remaining existing panel and trim on the bench. finally tack all in place ane measure again, once your happy weld carefully so as to not distort or twist the parts.

Good luck.

JP

[MK1_Oz]

Thanks guys. Did it a few hours ago and am very happy with the result. I decided not to separate the panels (mixture of 'too much effort' , all spot weld drill bits blunt and damaged and impatience).

After taking all suggestions onboard I ended up following my original line of thought. I cut off the old chassis leg to the required length (req length being for the inner skin), then held up the new panel (I forgot to mention that this had already been cut to the correct size to eliminate all rust area - sorry, sorta major info to leave out I know ) and marked the cut lines. Once the old inner wing was removed I then peeled off a little more outer skin on the old rail then welded her all up then made up a new outer skin section. I still have to grind down my welds when I am at so as yet I am undecided just how much I will grind.

Thanks for all your suggestions. I may do the other side and will probably use one of the alternate suggestions for that.