Chilly repairs
Too cold for adhesives, but not for metal fabrication
That quiet time at the start of January had been earmarked for the use of Sikaflex bonding sealant but continued daytime temperatures of 0˚C in Somerset ruled that out, with a minimum of 15˚C recommended. But all was not lost, as the two front rear inner arch panels I had to fabricate from scratch needed careful fettling to get them correct. I was ditching the original GRP panels in favour of 2mm aluminium. The originals don’t fit correctly because they were probably from another Peerless and needed numerous repairs regardless. I have already covered fabrication of the rear rear inner arches in PC, again using aluminium, but there is a difference. These new front inner rear arches need to be removable so that the filler neck, and fuel tank outlets can be accessed. Originally, they were simply screwed or pop riveted in position. The resulting muck and dirt that got past them wreaked havoc inside the sills, corroding the chassis tubes and fuel tanks. I wanted to eliminate that weak spot on my Phase 1 car by creating permanent cover frames, Sikaflex-bonded to the shell but with easily removed covers. Once fitted and sealed using butyl sealing strip (Dumdum substitute) the covers will probably not be disturbed for years. I’m hoping for a reduction in road noise, too (cue belly laughs
from fellow Peerless owners).
Arch works
A trial fit of the old inner arches with the filler neck and hoses fitted gave me an idea of where additional aluminium was required on the new panels. Sikaflex needs
a 5mm-10mm bead for strength, so that was also factored in. I was adding a 15mm perimeter line to my templates to allow for 90 degree folds. This strengthens the panels and provides a solid mechanical fit for the Sikaflex. The curved GRP panels were then clamped to sheet aluminium and their outlines traced, adding the additional material where necessary. The aluminium would be fitted so that the checker plate design faced inwards while the smoother surface faced the wheels.
I use a jigsaw to cut sheet aluminium as it takes no time at all and is more accurate than using a cutting disc, especially where curves are involved. A series of slots were then cut from the edges to the perimeter line to allow the 15mm folds to be made more easily. To create the folds I simply used large mole grips along the edges folding by 20 degrees and an inch at a time.
The panels were then given a slight curvature using my knee as leverage. 2mm chequer plate is strong stuff but can be worked easily enough. Then the panels were trial fitted. The passenger side was a reasonable fit that needed fettling to its straighter edge, but the driver’s side was better, and needed just a knee tweak to the curvature.
Happy with their fit, I now had to cut out the access covers. Two drill holes large enough for the jigsaw blade were made at either end and the covers cut out. Being a belt and braces kinda guy, I wanted the covers to be strong, waterproof and long-lasting. I could have made a retaining flange to hold the covers in place but I chose instead to make oversize cover covers using the old GRP panels. These were then riveted to the aluminium, starting at their centres and working outwards to retain the curvatures. I have used Rivnuts to secure the covers to their frames. The covers are now more substantial and once painted and coated in special sound-proofing underseal will blend into the blackness of the wheelarches.
Finishing touches
That left only the small fill-in pieces to make at the back of both sill ends. Card template outlines were transferred to 5mm GRP pieces with right angles, remnants of the excellent sill sections made for me by Option 1. With these fitted, the sills will be fully weathertight. Once the weather and ambient temperatures improve I’ll be using Sikaflex to make these repairs permanent. In the middle of all this, the carbs’ air filter box housing arrived, kindly sourced and sent by Matt George and dad Keith, from the store of Triumph 2500TC spares they have between them. The fuel system is nearing completion.