An Introduction: Chris Collins and Morris Tilly Project

[jack neville]

So having finally sorted computer problems out I can continue updates on Tilly Two known as Milly. Chassis was mostly stripped awhile ago and it sat on stands outside my shed although undercover. The last bits were removed by Chris, these being dash wiring and firewall fittings which had been left to copy so everything on Scrappy was refitted as it should. Getting Milly into the shed for examination revealed her to be far worse than we had ever noticed. Rust in the floor and sills is extensive. Half the battery shelf has disappeared and had a large patch over it. This was removed and an interesting item discovered
(more about that later),

[jack neville]

The biggest problem was the vehicle had been in a collision taking a hit on the left side just behind the B pillar. The left chassis rail was pushed in and the rear floor buckled. This had never been straightened but cosmetic repairs had been carried out and the full extent of the damage disguised. This vehicle was actually a runner when we first purchased it so the realignment of the rear axle cant have been too bad but it was obvious.
Problem was the fragile condition of the vehicle meant trying to push out the chassis damage with a Porta Power meant there was nothing strong enough on the right side to push off.
The rear cross member was also rusted out and needed replacing but fortunately the rear floor chassis section was still good so I decided the drill the spot welds and remove the floor panel so it could be straightened individually.
I could the fabricate a new cross member and with these parts removed it meant the rear chassis rails could be more flexible.

[jack neville]

With the floor removed I welded some bracing to hold the remainder in shape to prevent hopefully any dramas from being rolled around at my sandblasters.

[jack neville]

I thought it looked bad before it went to the sandblasters but what was revealed on return was even worse but at least it was clear what we were up against.

[jack neville]

It was clear the rust was worse than we thought.

[jack neville]

First to do was straighten the rear floor and get the rear end rebuilt.
I fashioned up a jig using some scrap and nuts and bolts. Welding some pieces to the joining seams on the floor I was able to pull out the main crease in the centre. I then attached the jig to the front creased area doing the same. Came out pretty good.

[jack neville]

Next was to fashion an new rear cross member and attach that to the rear floor. A bit of patching on the upper part of the right chassis rail was done first.
The cross member was first tacked into the rear corners and then a porta power used to push out the left side chassis rail until all the original spot welds i had cut realigned.