I am fortunate in that I was, at the beginning of the summer holiday, able to trailer the TVR chassis into school, where I can work on it in a proper engineering workshop, with a MIG welder far better than my one at home....
So carefully, with the chassis upside down on trestles, the rusty lower chassis tubes were cut and replaced one at a time (to maintain geometry). All new tubing was internally sleeved and rosette welded as well as seam welded. This is the correct way to join tubing end to end.
The tubes forward of the outrigger cross tube were replace one at a time..
Before the rotten cross tube and tube sections behind were cut out.
Wow that's a lot of tubes to reconnect!
The new outrigger cross tube was tacked into place..
Note excellent use of bungees to hold tubes together (idea cadged from the rebuild diary I photographed)
The rear suspension bracket was salvaged from the rusty section I cut out. Here it is just slid on and will be properly aligned and welded later.
You can clearly see the 2 spot welds either side of the join. These are the "rosettes" and there are 3 spaced around the tube either side of the seam weld.
Had to stop for the day here, but this joint is all ready for welding and you can see the "rosette" holes and the internal sleeve beneath. This is the system that American NASCAR engineers use to repair crashed racing cars, so it should be good enough for me!!!
All in all not bad for one afternoon's work. Quite nerve wracking cutting large chunks out, but very satisfying seeing lovely new tubes going in.
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