Peugeot 106 1.1 1997 - Welding - DIY

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Mon 20 Feb 2017 19:52
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

Hi,
Just wondering....
Looking under the back arch of my little princess warrior ,
1997 peugeot 1.1 ,petrol, 60 and a 1/4 bhp :)

I noticed the paint was coming away , only very slightly..but.. tapping around.. bits started to fall off !

i103.photobucket.com/albums/m147/liammcl_2006/whee...g

I spent ages making a template (which I am starting to think that I don't need?)
i103.photobucket.com/albums/m147/liammcl_2006/whee...g

Thankfully, it seem like the good metal isn't too far away
i103.photobucket.com/albums/m147/liammcl_2006/whee...g

i103.photobucket.com/albums/m147/liammcl_2006/whee...g

I sprayed some cold galvanizing zinc..
and fabricated a botchit (to last a few days , as protection from the rain) from a computer case's side panel 0.7mm?
i103.photobucket.com/albums/m147/liammcl_2006/whee...g

I'll get the proper 1.5mm mild steel sheet , very soon.
When I started cleaning back the rust... it seems? like there are no rust holes into the boot, so I'm wondering if I can leave as is... (filing down any sharp edges)

or do I need to weld that carboard template on, just to make it look like the other side.

I did all this outside on a pavement , with a generator inside the car..away from home, so as not to annoy the neighbours , and for the neighbours not to annoy me :)
i103.photobucket.com/albums/m147/liammcl_2006/whee...g

(This was a temp botchit to stop the rain going into that big hole, and rotting the insides.)
The welds suck, but did the job as "temporary glue"
... the generator 2000watts didn't have enough *oomph*
... the fabricated panel was too thin anyways, (computer case)
...it was raining,
... and I'd forgotten my welding helmet.

i103.photobucket.com/albums/m147/liammcl_2006/whee...g

but ! after some of Poundlands finest acrylic bathroom sealant, and a quick spray, it starts to look half decent (even tho' it is deffo not !)
i103.photobucket.com/albums/m147/liammcl_2006/whee...g

I wonder how many back street garages, just tacked metal on and then used epoxy , or metal putty to cover the holes..
www.toolstation.com/shop/Automotive/d60/Car+Body+R...1

I'm going to use back-step welding, slowly and letting it cool , then grind it down, and "metal putty" over the top of the welds.

This is very quick and rough..I was testing settings for penetrarion , torch angle, etc... and I'm hoping this would do for a MOT pass ?
i103.photobucket.com/albums/m147/liammcl_2006/Weld...g

I'm hoping that it doesn't need to be seam welded around there, as I am using gasless wire..and don't have any gas.
..I have seen professionals on the web, using tack welds, and /or plug welds

Anywho...this is what I've been up to .
s103.photobucket.com/user/liammcl_2006/library/whe...1

s103.photobucket.com/user/liammcl_2006/library/whe...1

The other concern, is that straight inder the botchit plate, at 90 degrees (running parallel to the floor) is a hole, which is next to a structural beam)
I reckon I could weld that too... it'd be a lot easier up in the air, but I shall do it lying under the car in the wet
...proper wet neck style :)

(a wet neck, is like a red neck, but we don't get any sun in Manchester to burn our necks :) )

i103.photobucket.com/albums/m147/liammcl_2006/whee...g

ps, there's other things soon? to go on mine, the rear axle is splaying out
and the diy timing belt has lasted 50,000 miles.. it must be due for a trip over the "timing belt rainbow bridge" soon..

i103.photobucket.com/albums/m147/liammcl_2006/Timi...g

I have seen a 20,000 mile 106, with 12 months mot, for £450.Mot History clean as a whistle..2000 miles a year, one lady driver ..would I be right in thinking that the clutch would've had a battering, on the short trips..

Cheers
Liam

Edited by liammcl on 20/02/2017 at 20:01

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Mon 20 Feb 2017 20:32
Peugeot 106 1.1 1997 - Welding - DIY - Wackyracer

Hello Liam,

This is a well known rust spot on Saxo's/106's there are 3 layers of metal there spot welded together and it seems water ingress gets in between the layers and rots them.

If you look on the mig welding website there is a Pug 106 on the forum section with photos of how the chap repaired it.

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Mon 20 Feb 2017 20:36
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

Many Thanks,
WackyRacer.

Will do..

Wow ! there's loads of posts...
www.mig-welding.co.uk/search.htm?cx=00657996850577...3

That'll keep me in mischief for a while :)

Cheers
Liam

Edited by liammcl on 20/02/2017 at 20:40

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Mon 20 Feb 2017 20:52
Peugeot 106 1.1 1997 - Welding - DIY - gordonbennet

That lady owner 106 is well worth having a poke nose at, considering what you get get up to on the old one, you must know the model inside out now, a 106 clutch you could probably do one handed in your lunch break whilst munching on a bacon and egg sandwich with the other hand.

Good to see you're still at it Liam.

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Mon 20 Feb 2017 21:07
Peugeot 106 1.1 1997 - Welding - DIY - Wackyracer

That lady owner 106 is well worth having a poke nose at, considering what you get get up to on the old one, you must know the model inside out now, a 106 clutch you could probably do one handed in your lunch break whilst munching on a bacon and egg sandwich with the other hand.

Good to see you're still at it Liam.

Agreed GB. A look at it's MOT history online may tell a story of it's condition.

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Mon 20 Feb 2017 21:27
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

Definitely , Wackracer !
That MOT history (with advisories) is a god send

www.gov.uk/check-mot-history

This is the £450 car , 12mths mot, 20,000 miles

i103.photobucket.com/albums/m147/liammcl_2006/Wipe...g

i103.photobucket.com/albums/m147/liammcl_2006/Wipe...g

That is very impressive
2 bulbs
and windscreen wipers !

cheers
Liam

Edited by liammcl on 20/02/2017 at 21:29

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Mon 20 Feb 2017 21:18
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

haha :),
Many thanks GordonBennet :)

tbh, I do want to do a clutch replacement,
I keep hoping mine'll go... but my stooOpid flipping car never breaks down :)

The wheels are splaying at the back, of mine..
so I'm hoping to replace the rear axle soonish.
(when the wheels starts rubbing on the arch liner)

Maybe I'm getting lazy, or have more money than sense these days,
but that £450 , 12 mths one, does look good..
I know it's a lot of money to be throwing around , on a new car ...
but it'll impress the neighbours :D

Saying that...I've replaced so many parts on mine,
it's almost a good car now :)

Great to see you too Gordon,mate.

All the very best, to you and yours
Cheers
Liam

Edited by liammcl on 20/02/2017 at 21:20

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Tue 21 Feb 2017 13:24
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

ps just for future tinkerers :)

Apparently, a continous seam weld
doesn't need to be done in one sitting, from beginning to end.
This would be a nightmare with gasless, as it would blow through ,
or look good, but not penetrate enough.

Seam welding, can be lots of little welds blended into each other.
I did the back step welding.. doing a spot..taking breaks..coming back next day etc
and then ground it down.. (filling in any tiny holes ...)

i103.photobucket.com/albums/m147/liammcl_2006/Weld...g

Let the tinkering commence.

I have just bought a fire extinguisher , just in case :)

Cheers
Liam

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Tue 21 Feb 2017 19:02
Peugeot 106 1.1 1997 - Welding - DIY - Wackyracer

I spent alot of my youth welding up cars with a MIG, some were my own and others were MOT's failures of people I knew. My fire extinguisher was an old fairy liquid bottle filled with water, that worked well for putting out underseal fires.

If I wanted to do a continuous seam without distortion or blowing a hole I used to (and still do) clamp a brass block on the rear of the panel.

Here is a couple of photos of the Midget I did when I was young.

www.dropbox.com/s/7cxuo0tpnhg1xsm/Spring_box_repai...0

www.dropbox.com/s/oohui5elpzve99b/Spring_box_repai...0

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Wed 22 Feb 2017 00:29
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

Yes WackyRacer !
I have a spray water bottle near by... it is great to cool everything off quickly

The dry powder, is incase it all goes pear shaped ..big time :)

That is some impressive welding , you've done there !
It is almost a dark art... !

On the welding forum, someone, quite rightly has said that the rest of my car will have loads of rust about, in other places...

I'll put it in for the mot and see what happens..

Cheers
Liam

Edited by liammcl on 22/02/2017 at 00:58

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Wed 22 Feb 2017 11:11
Peugeot 106 1.1 1997 - Welding - DIY - Wackyracer


On the welding forum, someone, quite rightly has said that the rest of my car will have loads of rust about, in other places...

I'll put it in for the mot and see what happens..

The 106's do rot quite alot underneath. you'll probably already have read the boot floor and support section, the front chassis rails behind the front wheels and the front inner wings from the suspension top mounts forwards all rust. Even some of the late 2003 cars are rotten.

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Wed 22 Feb 2017 21:29
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

WackRacer,
I've just had another look at your pictures..

The fabrication of the steel sections is outstanding !
I have no idea how you do that...I would probably , try and use a hammer to knock mine it into shape..

Can I ask?,
I'm looking at 1.5mm mild steel, is that an "ok" kinda size for botchit-ing. I'm only doing it to get past the mot.. and at maximum for it to last another year or two, no more.

A supplier mentioned zintec, but I'm not sure if I could weld it at 1mm...and the fumes are a killer !

Would I notice a huge difference bending and shaping 1mm, 1.2mm, or 1.5mm
and in the welding?

I think I'll wait to nearer the MOT time (end March)
as it is too wet for me to be climbing under the car in the entry, in the wet, using mains powered welders and grinders.

I know, I am a wuss :)

Cheers
Liam

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Wed 22 Feb 2017 21:34
Peugeot 106 1.1 1997 - Welding - DIY - gordonbennet

I agree with you Liam, both about the quality of Wacky's work and not trying to weld lying in a puddle..:-)

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Wed 22 Feb 2017 21:39
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

lol, thanks Gordon :)

"welding in puddles is for drips" :)

Cheers
Liam

ps, I was half looking at the idea of converting the yard into somewhere to work on the car.
I was thinking of taking that middle post out , and then I could drive in.

i103.photobucket.com/albums/m147/liammcl_2006/Weld...g

atm, I would have to weld in the entry, but the neighbours use that to get up and down...
i103.photobucket.com/albums/m147/liammcl_2006/Weld...g

Dunno, if the slabs could take it...for safety, I suppose I would have to put 4 inches of concrete down.
But, I could put some perspex up & be able to tinker in the dry.

Maybe even a pit, with a dolly to slide the car in through the gap.
..nah.. that seems like overkill atm

Edited by liammcl on 22/02/2017 at 21:47

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Wed 22 Feb 2017 22:17
Peugeot 106 1.1 1997 - Welding - DIY - Wackyracer

WackRacer,
I've just had another look at your pictures..

The fabrication of the steel sections is outstanding !
I have no idea how you do that...I would probably , try and use a hammer to knock mine it into shape..

Most midget panels are available off the shelf, the floor, wheel well and box section end patches were easy to make. A photo can make things look alot better than they are in real life.

Can I ask?,
I'm looking at 1.5mm mild steel, is that an "ok" kinda size for botchit-ing. I'm only doing it to get past the mot.. and at maximum for it to last another year or two, no more.

Too thick for what your doing, it will make it difficult to cut and shape.

A supplier mentioned zintec, but I'm not sure if I could weld it at 1mm...and the fumes are a killer !

You could weld it. wear a mask for the fumes. I used a piece of 1mm zintec to patch the floor in my van.

Would I notice a huge difference bending and shaping 1mm, 1.2mm, or 1.5mm
and in the welding?

1.5mm could be hard work, try and use something close to the thickness of what you're repairing.

I think I'll wait to nearer the MOT time (end March)
as it is too wet for me to be climbing under the car in the entry, in the wet, using mains powered welders and grinders.

I know, I am a wuss :)

Cheers
Liam

If I were you, I'd give the whole car a good looking over for rust and if it's rotten in the other known rot spots, I'd be looking at buying the other one for £500. I'd rather change a clutch than spend a few days grinding and welding. (that's assuming the other car isn't rotten too)

Edited by Wackyracer on 22/02/2017 at 22:30

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Thu 23 Feb 2017 00:30
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

Many thanks :)

Cheers
Liam

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Wed 22 Feb 2017 21:38
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

The 106's do rot quite alot underneath. you'll probably already have read the boot floor and support section, the front chassis rails behind the front wheels and the front inner wings from the suspension top mounts forwards all rust. Even some of the late 2003 cars are rotten.

Ah.. no , I didn't know that !
lol, it's like a "hole" new world to me ! :)

I suppose any 106 I get will have the same isssues I have..
all prone to fail with a poke of a stick.
I suppose it also comes down to the individual mot inspector too.

I'll do the welding of the holey part when it's dry,
put it in for the mot
and then decide...
who knows, something may go "bang" or "twang" before the mot date...

just thinking out loud...
I quite fancy a van, as I could do deliveries (courier) then..
as my computer repair malarky is going by the by...
but I want to be able to repair the van myself... with basic tools
and I suppose, the only ones like taht , will be old,
and will have rust problems themselves...

Cheers
Liam

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Fri 24 Feb 2017 11:15
Peugeot 106 1.1 1997 - Welding - DIY - edlithgow

If you get an ex-BT Sherpa (demountable) box van, its got a U-channel chassis so serious rust is restricted to the cab unit and is likely to be non-structural.

Probably hard to find these days though.

www.flickriver.com/photos/38389354@N07/4026394928/

www.lightstraw.co.uk/ate/tec/te/te_b865dvx_320.gif

Edited by edlithgow on 24/02/2017 at 11:36

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Fri 24 Feb 2017 11:30
Peugeot 106 1.1 1997 - Welding - DIY - edlithgow

Dunno if this'll be any use to you since (a) you seem to be doing pretty well anyway, and (b) I've only done it using gas, but in the right situation flange welds are the bizniz.

I replaced the bottom of some box sections and fabbed two chassis outriggers and put them together using continuous seam flange welds and they pretty much welded themselves despite my low skill level.

Maybe not so suitable for MIG since you dont actually need any filler metal. Probably work OK with stick (perhaps with a carbon electrode) or even TIG, but probably not as easy as with gas.

Snag is it won't look original so its likely to get close inspection, but mine survived a very thorough non-regulation hammering from the inspector.

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Fri 24 Feb 2017 20:21
Peugeot 106 1.1 1997 - Welding - DIY - liammcl

Thanks Edithgow,

I should be ok, with the mig.
tbh, it doesn't look that difficult.... (famous last words :) )
it seems time consuming for a beginner like me.

If I make mistakes, I can just grind it down and lay some more weld on top.

I may have to do 2 pieces and weld together to get the right 90 degree shape..and then make sure there's no sharp edges, ...or sharp angles too.

It should be fun, on a good day.

Cheers
Liam

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