Repairing Rust in Doors and Front Guards - HX One Tonner Build

[@allanbrowne111]

I have just newly subscribed once I watched this video. Im a spray painter (in my 50's), so love older girls being restored. For the sill repair, I would cut along the top, and then use wedges spaced out in the cut so you can get the straight line. Then once straight, either weld where possible or use thin strip sheet metal to make up where you have larger gaps. Nice progress though on the car so far.

[@ShenkeGarage]

Thanks for subscribing mate. I literally done this yesterday and it worked out. I have it all tacked and it sits nice and flat now. Just need to fill it in. A few people were saying replace the whole sill but the train of thought we both had saved a couple of days replacing the sill.

[@andrewhallett-patterson9778]

Impressive welding skills Sam. Admittingly mine are absolutely woeful due not to understanding principles but lack of physical activity. If you ever require to gauge weld penetration and saturation, invest in a magnetic dye kit, used to visualise weld penetration and error identification. Very easy to use, giving a professional visual perspective on your techniques. This is an inspection tool utilised within fabrication workshops daily. Looking forward to the next vid. 👍👍🇭🇲

[@ShenkeGarage]

Thanks for the advice Mate. I will have a look into that

[@craigkeating3432]

Currently restoring one atm iv got the doors to do tomorrow same spots but alot more damaged cheers for the vid I didn't know where to start

[@brockphilpott8740]

hey mate my brother has just brought a hx ute that needs some love,thanks for your vid mate very very informative,i think where in for a few unexpected moments ourselves,cheers mate

[@ShenkeGarage]

No dramas at all. There are plenty of videos on the channel on the HX so there should be a video for just about any repair that you need to do. Hopefully your HX is not too bad.

[@GeeenJ]

good repair on the door the way to align the right guard is they used shims under the radiator support bush where it bolts to the frame iron on the front it raises the apron up to allow the guard to line up with the door some had up to 1/4 inch shims to get them to line up

[@ShenkeGarage]

Thanks for the advice mate. I will try shim that like you say and see if I can bring the guard out at the bottom a bit.

[@gogogeedus]

You need a solid piece of brass for filling holes,just put the brass behind what you are welding,it will stop the weld falling through the other side.works wonders.

[@ShenkeGarage]

Yeah I have been meaning to get a piece but just never got around to it. Can get by but yeah I think it would make it easier for sure

[@FilmMastersChannel]

Just a FYI, when you door door jams make sure you put the weather seal on first. Sometimes that also helps to make sure the lines are correct.

[@ShenkeGarage]

Cheers Mate

[@unitbrown8655]

Well done mate, got me all inspired to start working on the old EJ Holden in the shed

[@ShenkeGarage]

Thanks Mate. Glad the videos can give you some inspo.

[@JasonSallese]

Congratulations on 3K, HX is coming together nicely.

[@ShenkeGarage]

Thanks Mate!

[@nexgenrevamp2976]

getting close sam . looking good

[@ShenkeGarage]

Cheers Jim

[@karlringe9523]

Hi mate. Your doing well. Real well. With your stone parcel tray that's not straight, your idea is the only way to do it. You might just need to cut the out lip and do as your first thought said. Its easy as! Thanks

[@ShenkeGarage]

Hey Mate thanks heaps. I started this today and it worked out pretty good. I just pry out the steel and tack and work my way along. Only problem is there is a big gap but I think some 3.2mm filler rods in between should work.

[@karlringe9523]

Yes for sure. Your all over it!

[@claybrien420]

It's coming along nice just a shame Stanny weather is not as warm then Brisbane otherwise I would have done more on my one tonner through winter

[@ShenkeGarage]

Thanks Mate. I am not complaining about the weather I have. It does get cold but not bad enough to not want to work in the shed.

[@mickholgate3347]

well done Sam, good job as always mate.

[@ShenkeGarage]

Thanks Mate

[@bigal878]

Great job Sam. Keep up the great work 👌👍🏻

[@ShenkeGarage]

Cheer there Big Al

[@craigkeating3432]

I found the full boar gasless mig welder from bunnings was the best for spot welding don't have to grind it back

[@Gus_Davidson]

Sam, great content as always; equally your vids are well produced and the music overlay is also excellent 👍🏻

[@ShenkeGarage]

Thanks Bud. Some people don't like the music but I like the whole synth/retro vibe :)

[@jakeausten9052]

have been loving these vids mate. so much motivation for myself, much the same as you just about to pay for my shed and build that in the next few weeks and then pull my tonner out of storage. mine shouldnt have to much rust im hoping but so keen to get stuck into it cheers

[@ShenkeGarage]

Cheers Mate. Glad the vids can help with some motivation. Exciting times to get the shed built and get the Tonner in there. Was a good feeling building the shed, getting set up and finally seeing the tonner in there.

[@TheShedSesh]

Nice one mate. You really get in there to fix it properly. Great to see.

[@ShenkeGarage]

Gotta be done right the first time 👍👍👍

[@MickMcN]

What about a slide hammer or dent puller for the sill?

[@jimrussell1446]

you are doing a great job a little bit at a time

[@ShenkeGarage]

Cheers Mate. One job at a time and eventually will run out of them.

[@trevorsmith9251]

Looking great, definitely not many doors left that are good or affordable, did you ever do a video on your background in cars or fabrication skills?

[@ShenkeGarage]

Thanks Mate. Yes agree. People asking stupid money for good ones. I have not done a video like that. I try not to talk too much about myself.

[@lordterrabyte1417]

Every time I watch you work I look at my hz one tonner and think its time to make a start, I've only had it for 12 years so far lol

[@ShenkeGarage]

Better late then never Mate

[@Wanker59]

Good work

[@ShenkeGarage]

Thanks Mate

[@ajod5360]

Another excellent video. Your work is a credit to you. Looking forward to seeing you split and build out the centre of that sill (cant see any easier way to fix it).

[@ShenkeGarage]

Thankyou Mate. Yeah there is no way unless cutting it open unfortunately.

[@AnthonyVeith]

If possible could you get behind the sill with a portable ram and slowly push the sill out , might be easier to cut a section from behind to get the ram in then weld back once done

[@ShenkeGarage]

Hey Mate. There is an inner sill panel so access behind is not an option. I started repairing today and I think what I have done will work.

[@walkaboutwarkie4897]

Thank you mate as your giving me confidence and the know how to take on more than I ever would have before watching, thanks heaps champion!!

[@ShenkeGarage]

No dramas Mate. Glad the videos can help out.

[@jono7017]

Hi mate, loving your vids. Doing up an hx ute myself - can I ask did you weld with gas or gasless mig?

[@tomspeirs1195]

Congrats on 3k subscribers mate. Just wondering if you could tell me the settings on your welder for panel repairs? Are you using 1.2mm sheet steel? And is it cold or hot rolled?

[@ShenkeGarage]

Cheers Mate. Yep using 1.2 mm cold rolled steel. I will have to get you the settings tomorrow but im using .9 wire

[@billipiro36]

Great vid Sam. Your really making a habit of that

[@ShenkeGarage]

Thanks Mate 👍

[@Kris-it3nh]

Great job 🤙

[@ShenkeGarage]

Thanks Man

[@leeroy6526]

Have you thought about the wildwood brake booster delete kit to tidy up the firewall even more

[@ShenkeGarage]

Sure have. Already own one 😁

[@willziesgarage7143]

Body work looks fresh af man, coming along great. Love how in-depth your videos are. Can’t wait for the next episode to come out, have you thought anymore about the door handles man?

[@ShenkeGarage]

Thanks a lot Mate. Trying to add as much detail without rambling on and making it less interesting. I think I will shave them off. I have a couple of ideas on how I will do this

[@willziesgarage7143]

@@ShenkeGarage well you’re doing well haha. Yeah that would be sweet. Sounds good man. Can’t wait to see it done!!

[@williamduffield4964]

should just unpick all the factory spots to take off the inner skin and repair the hole inside of the door. It would just be easyer

[@rizzler1023]

might be time to buy a (weld slide hammer) for your sill repair mate. really enjoying watching this build series.

[@ShenkeGarage]

Thanks Mate. Yes was thinking about getting one. Might need one now perhaps

[@brettsuckling2095]

The simplest way to do the sill would be stud weld and pull the area out. It won't be the fastest. Just the simplest

[@shillosspeedfactory1642]

Legend! Done well mate

[@ShenkeGarage]

Cheers Mate. 👍

[@stephennummie7631]

Should try a shrinking disc to bring the lows up Watch a guy called pro shaper workshop shows you a lot of information

[@ShenkeGarage]

Cheers mate will check him out 👍

[@craigkaschan4822]

That door is knackered. Typical of 70’s Holden’s. I’d source a new couple of doors if you are going to keep the vehicle.

[@ShenkeGarage]

It seems ok now after doing the repairs to it?

[@jackthomson73]

Congratulations on 3 k mate. Are you going to register this or show strip only. Mate of mine is doing something similar and is having trouble getting the top welded suspension brackets through engineering

[@ShenkeGarage]

Thanks Mate. It's actually currently registered. I'm not actually too sure what I am going to do. I think engineering is going to be a hassle.

[@jackthomson73]

Yeah I think your right. My mate is dropping a 66 Chevy c10 body on a hq tonner chassis and found out that he can’t get engineering for a four link because it never came with a four link set up and you are not allowed to weld suspension brackets on chassis. We made a frame that bolted on to chassis then welded the top brackets to that. Apparently he has an engineer that will approve it. Most of the legalities are way over my head but if want more info let me know and I’ll try to hook you up with my mate. 👍

[@stephennummie7631]

Should try a shrinking disc to bring the lows up Watch a guy called pro shaper workshop shows you a lot of information on metal work

[@williamduffield4964]

You have the mig running slow.

[@01spikyspider007]

thanks champ.. make it real

[@ShenkeGarage]

No dramas at all

[@MartinDoms]

That door was a real bastard eh. Great video, as always.

[@ShenkeGarage]

Was a bit more work than expected but seemed to end up ok.

[@adamheazlett1179]

You know the saying opening up a can of worms.Normally you see 20 % of rust till you really start looking.Depends on your time frame no one can afford to pay someone these days for a good job not bog

[@ShenkeGarage]

Agree with paying someone. I have spent many hrs and would hate to think it would all cost to pay someone an hourly rate with all the repairs I have carried out.

[@adamheazlett1179]

@@ShenkeGarage Keep up the good work.Had a 71 Tonner with statesman front gts guards 327 glide.Picked it up after a tune went for a run broke a tailshaft ended up 4 foot above the road .Cost me $600 to put back on the road with heavy tailshaft and new headers and enamel paint.back in 1983 times have changed and it had no rust.Cost me $1600 when I bought it 12 months rego

[@timwhalan6417]

👍🏻🍺👏

[@randywatson6114]

Talk to graham from Xacoupeguy on YT he might be able to point you in the direction you need.

[@randywatson6114]

In regards to the sill

[@ShenkeGarage]

Will check out the channel. Cheers Mate

[@davidmccrory5604]

Good on sammy 3,000 subscribers and going strong ur a good aussie lad doing quailty work ur not full of yourself like some dickheads on you tube congratulations mate and im sure you will have 6,000 subscribers in no time

[@ShenkeGarage]

Thanks heaps Mate. I know what you mean about the dickheads. Just trying to put out some good Aussie content with Aussie Muscle

[@williamduffield4964]

You need to go and learn how to do metal shapping.

[@ShenkeGarage]

Mate you have commented 6 times criticizing my work. I have never said I'm an expert at anything I have done. I'm having a crack and I am happy with what I have done so far. I'm documenting this build to show how I am doing it with little experience and limited tooling in a shed in the backyard.

[@williamduffield4964]

@@ShenkeGarage Not quite, the fire wall is looking awesome and love the new look above the doors on the edge of the roof. Just been making comment about things that should make it easy. Not ment to be negitive. The comment about the inside of the door at the hing plate, if you use a paper template to pust it into the odd shape then cut the paper where it needs the flaten the paper template out onto a new piece of metal you should be able to fabricate it in one piece Its just much easyer, its called metal shaping.

[@ShenkeGarage]

Ok no dramas. I appreciate constructive criticism. Just a few of the comments felt a bit negative when I had multiple comments come in around the same time. Apologies if that was not your intent.

[@stephennummie7631]

Should try a shrinking disc to bring the lows up Watch a guy called pro shaper workshop shows you a lot of information on metal work