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> Xyy81t's Zoe Progress Thread
xyy81t
post 13th November 2010 17:19
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I thought it was about time i started a progress thread and since i started to tackle my rusty floor plan this weekend i thought it was a good place to start!

so i set about this morning at stripping the interior out, and i must say i was supprised how simple it is to get everything out, the carpet needed a bit of jiggery pokery but came out fine in the end to reveal:

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looks like the driver footwell is a bit wet, not a good sign no3.gif so dreading what i might find in the front i started in the back and chibbled away at the sound deadening and found a few holes

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So i got on the blower to a local fabricator and got me some 1mm thick mild carbon steel sheet for 20, dunno if thats good or not but i got plenty to do the job so am happy with it. Then got me angle grinder out and cut out the holes and started to weld in a bit of the sheet i got.

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as you can see, it took me a while to get used to the thickness of the steel so was blowing a few holes in the beginning blush.gif but after a while and with a bit of practice i got on fairly well, i am now quite good at filling holes! rolleyes.gif

I got the plate semi - in before darkness fell so will have to wait till tomorrow before i can finish it off

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until tomorrow......


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langers
post 13th November 2010 18:17
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Good work so far, however, what you should have done instead of welding in all the high parts, is work from one end in, completely seem welding it all, as you get to each ridge, give it a good bashing with the hammer to get the shape and then weld that section in etc.

I put an air line under my carpet on the blue Junior for about an hour to dry it out (didnt take the carpet out for that one)



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xyy81t
post 13th November 2010 18:21
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well my plan is to push those bits up with a jack or hammer them if i can get her high enough. i did have a good look at your faq on it but couldnt quite work out how you did it so thought i'd wing it laugh.gif


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kirk46
post 13th November 2010 18:49
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sweet.... mine needs the interior out jobby to do under the rear seats.. so i will be needing help on how to get the interior out biggrin.gif

also how long did it take to take out the interior?

This post has been edited by kirk46: 13th November 2010 18:53


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xyy81t
post 13th November 2010 19:24
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QUOTE(kirk46 @ 13th November 2010 18:49) *
also how long did it take to take out the interior?


Not very long, 45 mins, an hour at the most. trickiest part was trying to manipulate the carpet to get it out (its formed from some kind of vacuum moulded plastic on the back so is real stiff)


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kirk46
post 13th November 2010 20:01
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wow, i was thinking of booking like a week off to do it laugh.gif


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QUOTE(groovylee @ 13th August 2011 08:41) *
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xyy81t
post 13th November 2010 20:16
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if i had any holiday left i would have booked a week off to do it. took me all day just to do that one plate, and thats not even finished!


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GialloEvo94
post 13th November 2010 20:25
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Good work. The way I planned to do mine was as per langers suggestion although mine's not as bad as yours as I only have one hole on each outer ridge of the rear footwell with all other ridges being fine. The way you're going to do it, I would use a blow torch to heat up the metal nice and hot to make it as soft as possible so it will stretch and form much easier into the corrugated sections when you bash it with a hammer. I probably wouldn't have welded a patch on both the top and the bottom because it will trap moisture from condensation inside the pocket where you can't do anything about it and corrosion on the bare mild steel faces inside the pocket will start it's evil work again almost immediately. But unless you want to cut the top plate off again then it probably isn't worth losing any sleep over.

Did you measure the thickness of the floor pan steel? If you did then I'd be interested to know how thick (or thin) it actually is.


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kirk46
post 13th November 2010 20:36
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i recall langers telling me the floor pan is 0.8mm think GE ohmy.gif


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QUOTE(groovylee @ 13th August 2011 08:41) *
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xyy81t
post 13th November 2010 20:38
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QUOTE(GialloEvo94 @ 13th November 2010 20:25) *
I probably wouldn't have welded a patch on both the top and the bottom because it will trap moisture from condensation inside the pocket where you can't do anything about it and corrosion on the bare mild steel faces inside the pocket will start it's evil work again almost immediately. But unless you want to cut the top plate off again then it probably isn't worth losing any sleep over.

i didnt , theres only one plate there, definatley dont want any trapped moisture no3.gif

QUOTE(GialloEvo94 @ 13th November 2010 20:25) *
Did you measure the thickness of the floor pan steel? If you did then I'd be interested to know how thick (or thin) it actually is.


i dont have the appropriate measure but from eye it is very close if not the same thickness as the plate im using which is 1mm thick


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GialloEvo94
post 13th November 2010 21:18
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QUOTE(xyy81t @ 13th November 2010 20:38) *
i didnt , theres only one plate there, definatley dont want any trapped moisture no3.gif

Ah yes, I can now see that you've butt-welded it using a single plate rather than overlap welds. Thought it was two plates but looking closer I can now see it's not smile.gif


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Smokin' Socks
post 14th November 2010 08:59
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Wow that actually looks worth than mine did! That's a fairly substantial piece of metal for 20 quids especially compared to the measily bit my Dad bought from B&Q for a tenner.

Did you have any trouble getting the carpet out from the driver footwell? Mine seemed to have a bracket from either the steering column or the pedal mount bolted though it and I had to cut off the very front of the carpet
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xyy81t
post 14th November 2010 09:07
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i didnt have to cut any of it, but it was kind of pinched in both footwells so a good tug and it came out. hopefully i wont have to remove any more interior bits to get it back in. i can see that being far more fidly


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Smokin' Socks
post 14th November 2010 09:18
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QUOTE(xyy81t @ 14th November 2010 09:07) *
i didnt have to cut any of it, but it was kind of pinched in both footwells so a good tug and it came out. hopefully i wont have to remove any more interior bits to get it back in. i can see that being far more fidly


Weird.. must just have been mine.

I don't recall getting it all back in to be all that fiddly. It all seemed fairly easy to push back into all the slots
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xyy81t
post 14th November 2010 13:35
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Stage 1 of floorpan restoration complete

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and now im knackered so im settling down to watch the F1 2010 finale! - no spoilers please nono.gif


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NaanBread
post 14th November 2010 13:43
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its an amazing race! the 1st lap was awesome! biggrin.gif


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kirk46
post 14th November 2010 13:59
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sweet

what did you cover the plate with mate?

@naan yep biggrin.gif

This post has been edited by kirk46: 14th November 2010 14:02


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xyy81t
post 14th November 2010 14:21
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Its just hamerite, once its dry underneath ill put some underseal on but inside that's all I'm giving it


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neilandbob
post 14th November 2010 14:58
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Good work, i'm not dissing it in any way but you would find it far easier to cut the plate bigger than the hole, clean up a section around where you've cut, then start to weld where your patch touches, as has already been said, as the metal heats up you can knock it in to shape, weld about an inch at a time, then miss an inch and so on, this way you'll avoid too much distortion. Finish the hole underneath with seam sealer then under seal/waxoyl when the sealer is dry.
I don't know how much welding experience you have but i'm amazed you've managed to butt-weld new clean steel to the Kit-Kat wrapper that an Alfa floorpan is made of! Keep up the good work, remember how much faster Zoe yellow cars are!


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xyy81t
post 14th November 2010 15:40
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This is the second time I've ever welded with an arc welder. I usef to have a fabrticating job about 8 years ago which I used a mig welder every day. What I wouldn't give to have that machine to do this.
Arc welding is so misleading, you think you,ve got a nice weld only to knock the coating off to see a farty little join. So you try to compensate and linger longer to get a thicker bead and hello holes!


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