By profession I am a Technical Officer for British Telecommunications and not a welder. I am more used to wiring up exchanges and driving computers!. However soldering is just low temperature welding, and many of the same principles apply.
So over the next few weeks I hacked, cut, and welded away in the garage...Its not that neat, but it isnt going to come apart either!

The engine and box were duly fitted in March, along with the newly repaired and painted bulkhead.
Its starting to look  like a Lightweight again!.

The next problem I encountered was one of the chassis engine moutings did not line up by about 2 inches. I am not sure what engine it was jigged for, but its not a 2.25, 2.5 or a V8. So out with the Welding Torch, and I modified the engine bracket with a piece of  GPO "C" channel from an old Telephone Exchange! Problem sorted.  I didnt want to modify the chassis as its already galvanised.

The next minor problem, was easier, the chassis has a 2 inch body lift, but the steady plates that mount between the bulkhead and the chassis wont fit, as the holes in the chassis would need to be in fresh air!... Again welding torch to the rescue, a simple extender plate was welded to the back of the bracket, thus allowing new holes to be drilled in the bracket and the bulkhead be supported again.
This also turned out to be a hidden bonus, as the chassis was fitted for power steering.  The problem here, was that it meant a change of steering column. A very nice 300Tdi one was obtained at Old Sodbury, which was just the job. Only difficulty was that there wasnt any suitable mountings for it. This was solved by a nice section on 3" x 2" angle welded to the new bulkhead mounting plate. The column is now very well secured, and lines up nicely with the box on the chassis. Although this will mean a small bit of surgery to the innner wing to clear the collapsable section of the column.

Double click on the pictures for the larger more detailed copies
So far, I have now got a rolling chassis with engine, box, and bulkhead fitted... More will follow as I get it done.
Oh by the way, the name "Flash Harry" has been given to it by my youngest lad. Yes thats right, he has been watching too many St Trinians videos again.  Hmmm Must try to get the Missus one of those uniforms!! 

Continued on next page
 
 

All Text and Pictures Copyright - G. Wilkin March 2000