My welding table and spatter screen

When I first got my Hobart Handler 140 MIG welder I would weld on the garage floor. This was not the best way to weld having to bend down or kneel to weld. I only had a small area to work with next to my work bench. I found a small fold able work bench on sale at Harbor Freight for under $15.00. I also purchased a 6' x 6' welding blanket. I bought a piece of 16 gauge steel the same width as the top but a little wider then the top. I welded some vertical blind weights I had on hand as a spacers to create an air gap when it is on top of the work bench. I also welded on two pieces of angle iron on either side of the center so it could be clamped in place by the bench top.

I built a light frame work out of 1" x 2" lumber to drape the welding blanket over to stop welding spatter. The pictures below show what I ended up with.

Work Bench with spatter screen

Back of 16 Ga. metal top

Metal top on work bench

Spatter screen frame work

Spatter screen frame work (another angle)

This setup has worked well for me. I can now sit comfortably and weld on small projects. I also can remove the metal and use it as a work bench with a clamping surface.

Plans for storage of the body removed from the frame

When the body is removed from the frame I will need a place to store it. My wife will not give up her side of the garage and I do not want to store it outside. So I found a posting on the 6-Pack forums here Body Off . I copied their design and drew it up in Google Sketchup. Below is what I ended up with.

The white boards are the 2x4's the blue are 7/16" OSB. I will cut the points off the triangles so they do not overlap when I build it.

The materials need are as follows:

Materials Quantity Source

2x4x96” wood 4 Lowes

2x4x105” wood 4 Lowes

4x8X7/16 OSB 1 Lowes

3" 1000lb casters 4 Northern Tool

1 1/2" wood screws 1-box Lowes

3" wood screws 1-box Lowes

3" Lag Bolts 16 Lowes

I will need to borrow my wifes side of the garage to build and store it until I am ready for the body lift.

I plan to lift the body using a 2-ton engine hoist. Here is an example from the 6-Pack forums here We have liftoff.

Removing seats, bumpers and body to frame bolts.

Finally decided this was the year to start are the repairs to get it back on the road. The biggest issue is the rust in the frame where the rear suspension trailing arms attach. I ordered the replacement parts from TRF. I purchased a Hobart Handler 140 MIG welder and cart to handle the welding.

The first task was removing all the panels in the Trunk and the spare tire. I already had the gas tank out to repair rust in the filling neck and seal it. I removed the seats, seat belts on the floor and carpet under the seats and in the foot wells.

Next was the front and rear bumpers. I used a chair I had is the garage to hold one end of the bumper I had removed the bolts from so it would not fall. The back side of the bumpers had some surface rust so I took the opportunity to clean with Orange Blast and a green scrubber pad. I then sprayed the rust areas with the Must for Rust. The next day I painted the inside of the bumpers with silver Rust Bullet.

The next item was to remove all the bolts that connect the body to the frame. There is one in the trunk that holds the tire, 1 on each side of the trunk in the rear of each wheel well, 1 behind where each seat was, 1 on either side of the small tunnel near the hand brake, 3 on each side near the rear of the each door opening, 4 on each side near the front of each door opening, 2 on each side of the dash support, 1 on each side of the foot wells, 1 on each side under the hood on the shock tower supports and finally one on each side of the radiator. I used PB Blaster on all the bolts and only one bolt head snapped off. The one in the drivers foot well.

Next I needed to remove the wind shield frame. I knew the driver’s side was stuck, a common problem, so I hit it with PB blaster over several days. It did not budge so I went to plan B, cut the mount to release the pin. I used a Dremel and it was a tight fit and I broke about 6 cut off wheels. After the cut was made I pull on the wind shield and it came right off. I will weld up the cut before I put it back on the car.

I then removed the 4 rear and 2 front frame to bumper mounts. I took some pictures of a dent in the rear valance that was hidden behind the bumper.

PROBLEM AREAS - 2005

Driver side front rocker panel

Driver side behind door

Driver side further behind door

Driver side rear wheel well

Driver side rear valance

Trunk driver rear corner

Trunk driver corner

Passenger side rear valance

Passenger side rear wheel well

Passenger side further behind door

Passenger side behind door

Drivers side headlight

Passenger side headlight bottom

Passenger side headlight top

All around view from 2005

Front View

Driver View

Rear View

Passenger View

TR6 Parts and repair records.

1973 Triumph TR6 Commission #CF11066U, Engine #CF11384UF, Exterior Color code 96 - Sapphire Blue, Interior code 11 - Black. Paid $3900 in June 1993.

Date	Mileage	Description
05/29/04		New tire Michelin X-Rad
07/20/03	113532	New steering rack boots and front end alignment. New brake master cylinder.
10/05/99		Rear brake drums turned, new pads and springs.
09/05/99		4 new tires 205/70 Michelin X-Rad
07/20/99		New bearings in rear differential, drill and tap for drainage plug and have rear diff mounts welded and boxed in with kit from TRF.
07/07/99		Balance drive shaft. Vibration a 55-60 MPH.
05/16/98	112,000	Oil change and filter (10w-40)
09/13/96		Install stainless steel falcon sport exhaust system.
09/08/96	110,665	Oil change and filter (20w-50)
09/01/96	110,637	Install new glass channel assembly in both left and right doors to cure annoying rattle. Also install new inner and outer door waist seals on both doors.
06/18/96	110,256	Have transmission rebuilt, It makes a whine and high pitch grinding noise. It is determined that the transmission has a ruined Counter shaft gear. So I obtain a used transmission and had it rebuilt. Also install new trans. Mounts and Poly steering rack bushings.
05/05/96	110,094	New points, Condenser and Rotor.
04/13/96	110,020	State Inspection, Change transmission oil with GL-4. Note: lots of metal shavings in oil and on plug magnet.
03/25/96		Oil change and filter (20w-50) Install new flexible steering coupling, steering u-joint and paint steering column. Install new carburetor linkage.
03/20/96		Install new windshield
03/17/96		Install new overflow bottle, cap, grommet, hose and bracket. Install new oil pressure switch.
02/25/96		Bleed clutch hydraulics
11/23/95		Rebuild brake master cylinder, minor rebuild vacuum boost, paint and bleed system.
11/11/95		New Halogen headlamp’s.
08/15/95		Rebuild front suspension. disassemble front suspension have all parts sand blasted and repainted.(new bearings, poly bushings, upper ball joints, outer tie-rod ends, steering rack boots) rebuild front brakes (new pistons, seals, flex lines, rotors, pads)
06/12/95	108,946	Replace 5 U-joints, differential pinion seal and refill differential. Replace left and right rear brake hoses and bleed hydraulic system. Replace left and right parking brake cables.
05/07/95		Install oil cooler
04/01/95		install battery cutoff switch and anti run on valve.
02/25/95		Remove carbs, intake manifold and exhaust manifold, disassemble carbs and send bodies to be rebushed, sand blast exhaust manifold, replace upper radiator hoses and clamps.
12/14/94	108,482	State Insp. Oil and Filter
09/25/94		new spark plugs
09/17/94		balance front wheels
09/04/94		Floor mats
07/19/94		Clean and repaint rims, new lug nuts, remove remount sway bar
06/16/94		fuel pump repair kit, filter screen, oil lube & filter
05/05/94		headlamp rims
04/30/94		top side seals, Velcro, remove and refinish dash, refurbish heater box and fan, clean instruments
03/07/94		door glass to windscreen seal
02/15/94		Glove box lock, switch plith, new battery
01/24/94		thermostat
01/18/94		water heater valve, breather hoses
12/16/93		Front bonnet seal
11/12/93		Interior rear view mirror, sport ignition coil, new ignition wires oil line to head, choke cable
11/05/93		push horn pad, license plate frames
11/02/93		install new rear suspension bushings, disassemble and lube splined axle shafts, install Rear comp grade springs, R inner U-joint, bleed brakes, oil lube & filter, state inspection.
10/27/93		front license brackets, fuel filter, radiator cap, rocker cover gasket, strip and repaint rocker cover and air cleaner housing
10/19/93		filler cap clutch M/C
09/20/93		Number plate lamp kit
09/08/93		Wiper motor mounting, L Door check strap, Rebuild & paint wiper motor
08/25/93		Owner handbook, bonnet release cable, dash top, L door mirror, knob set, R lower crash pad, Interior panel set
08/11/93		Seat re-upholstery, seat foam, diaphragms, installed
07/29/93		Horn push, L & R fuzzy seal, Console trim kit, bonnet buffer kit
07/26/93		Battery Box
07/14/93		R sun visor, window crank & door handle, L window regulator
06/29/93		L&R tail lamp gaskets, gearshift boot
06/24/93		Carpet & Under-felt, Plastic trans. Tunnel & propeller shaft tunnel, Flasher unit. trunk carpet
06/16/93		R&L rear turn signal, R rear side marker, Trunk trim panels, tool strap
06/15/93		Hood latch
06/07/93	106,000	Car cover Technalon
??/??/1993		2 new redline tires.
??/??/1993		New top.
10/06/92		Replace front break pads, left/rear brake cylinder, bleed and adjust.
06/11/92		Rebuild clutch slave cylinder & bleed system, distributor cap & oil/filter.
10/03/91		Radiator flush/refill, License & reverse bulbs & state inspection.
05/02/91		Change oil/filter, install spin on adapter, weld differential mounting bracket, replace pinion seals & mounting bushings
03/26/91		Tighten axle shaft, shocks & exhaust.
05/15/87		Install T/O bearing, clutch disk, pressure plate & clutch pin, remove broken pin, weld yoke, bush accel. arm, weld linkage, adj. timing, plugs, carbs, vacuum leak, install rocker arm screw, adj. valve & renew hose.
11/25/85		Install new front bumper assembly.
12/30/85		Link assembly(rear shocks to trailing arms) and nuts.
07/01/85		Mirror attachment kit, 2 horns, horn bracket, brake pressure diff. switch.
03/18/85		Install new rear bumper with left and right corners & overflow bottle.
12/29/84		Rubbing compound & mirror glaze & reseal.
12/21/84		Plug wire set, distributor cap & ignition coil.
12/15/84		Rebuild distributor.
12/07/84		Horn slip ring and insulator, horn brush, accel return spring & bonnet release cable clip.
09/11/84		Clip.
07/15/84	95,400	Exhaust front pipe, mid pipes, clamps & 1 U-joint bearing.
09/16/83		Battery.
07/11/83		Steering rack clamps, rack mountings.
11/16/82	89,686	Oil & lube, correct install of carburetor gaskets, tie rod ends & door handle.
07/22/82		Rear plastic window, carpet.
07/05/82		Body work, Paint?
06/24/82		Weld rust, repaint & clear coat?
05/01/82	86,052	Rebuild brake master cylinder, replace rear wheel cylinders & install new rear brake shoes.
04/14/82	85,689	Adjust rear brakes, replace front wheel bearings and seals, check engine on computer, major tune up, align front wheels, carb kit, plugs, points, condenser, air filter, inner & outer bearings, seals, oil & filter, carburetor diaphragm, ignition wires.
03/06/82		Repair rocker panels & 1/4 right/left, rear body, paint and clear coat.
02/05/82		Muffler, rear connecting pipes & clamps.
??/??/1982		Rotor.
10/30/81	82,000	2 Redline tires & tubes
08/12/81		Parts?
07/02/81	78,517	Clutch master cylinder, speedometer cable, condenser & oil change.
02/17/81		Replace alternator belt & bypass hose.
12/01/80		Sanyo car stereo.
08/15/80		Install new top.
06/28/80	71,811	Replace front wheel bearings, steering rack bushings, left tie rod end, upper ball joints, lower control arm bushings, rotate tires & align front end.
04/02/80	69,598	Replace front brake part & muffler Hanger.
03/14/80		Rebuilt alternator.
01/29/80	68,596	Replace clutch, pressure plate, bearing, front control arm bushings & steering rack pinion bushings
07/17/78	55,169	Tune up, points, plugs, oil/filter, hookup heater valve cable, change speedometer cable & rebuild brake master cylinder.
12/02/76		2 tires.
06/07/76		Replace clutch, pressure plate & bearing.
04/21/76		Clean brakes and bleed, lube left steering spindle, free king pin, points, condenser, set timing & idle & balance wheels.
04/01/76		New top.