Richard, you've jinxed me! I thought this welding business was supposed to be easy - all I've done so far is create some nice little bobbles of hot metal in between the machine's feed stuttering (brand new miller passport plus)  Time to read the instructions again!

Ok panic over - and thanks for the tips. After much checking of websites (miller included), reading of manuals and experimentation, I discovered that the main problem was that I tended to hold the gun too CLOSE to the metal - moved it away another 1/4 inch and managed to run a good few nice practice beads, so tried a small project - replace a  small section of rusty floor that I found while preparing the sill.

Here's what it looked like after my first attempt and subsequent treatment with a flap-disc.....


So I had another go - here's it is after the second one...


After a bit more work, it appeared not too bad. Some of the welds were a bit porous and had to be redone - a bit more practice needed, I think. Going by the rust patches I'm finding, I don't think there'll be any problem with that!

Well done for getting the rest of the photos up.

WOW, your really flying along, she looks good.
Front cross member and the engine mounts look in good condition.

What is all the black "gunk" on both sides of the firewall ?
Was there that much dirt, grease and other sh1t there, can’t believe she was that dirty or is that the sound insulation, definitely overkill.

Is that the fuel filter on the bottom by the bell housing.
If it is I have just replaced an identical one in MG but by mistake I got two new ones so I've got a nice glass and chrome one if you want a freebie.

Cheers,
Richard B.

Thanks Biggles.

Must say to myself  "NO I DO NOT NEED A WELDER, I DO NOT NEED A WELDER, I DO NOT NEED A WELDER !"
Bad enough that I went to Golden tools last night and got followed home by another tool box. 
It's not my fault all my new Imperail stuff meant i HAD to get another box.

Cheers,
Richard B.

Hmm a separate toolbox for the imperial tools, I like that. Mine came from GT s well - may have to go back.

To answer a few points..

What is all the black "gunk" on both sides of the firewall ?
Was there that much dirt, grease and other sh1t there, can’t believe she was that dirty or is that the sound insulation, definitely overkill.

Yep - the remains of the soundproofing....the bloody stuff was everywhere - even around the heater box, which fits it's slot like a glove!

Is that the fuel filter on the bottom by the bell housing.

Yep, that's the fuel line and filter - one of the few hoses that I don't have a replacement for yet - can't remember but I think I have a filter already in a box somewhere - thanks though.

What is the penetrationon the back side like ?

Poor at first - later attempts were better and did show from underneath. Am going to practice a lot more before doing anything that shows.
As for the porosity - I did get a lot of "seagull sh1t" at first, it was the later welds that had bubbles in them. I'm using 100% CO2 for shielding - the welder I'm using is supposed to be better with that than an Argon mix. As for supplies, It all came from a shop on airport road, abeam the petrol station at the cargo village - "industrial welding supplies", I think. They also sell zdx cutting / flap discs and loads of varied consumables / tools too. Ask for Ahmed. Feel free to borrow my welder / plasma cutter too.

Unfortunately, back to work today, so not much will be done until after the weekend.

Cheers,

Stuart.

Haven't tried that yet - comes off nicely with an air grinder and wire brush, though.

Just hope that mine doesn't end up like this...

http://www.joc.org.uk/phpBB2/viewtopic.php?t=10659

hope it's readable without a login this time.

Hey Nifty, thanks for the input - all comments welcome as I'm a complete newbie!

This particular weld was not what I would have hoped to start with as it was an overlap joint comprising 3 different panels - I did make a point of trying to clean up the "contact patches" but something tells me I could have tried harder! Frankly, most of the other areas are much more accessible, so I'll be certain to make sure they're properly cleaned up before starting - I did try running a few beads on freshly sanded steel as opposed to millscaled, so have some ides of the  difference it can make. Much practice needed, though.

As for

Good panel repairs arent just cocky sh*t welds and grinding and bogging. It entails beating with dollies and hammers and filing with a body file and lead wiping. Sounds very old school but its very rewarding when you do it right and it will last for years

Sorry if it appears cocky but, having never tried before, I have only the interweb and / or books at my disposal to learn from. It may mean that I waste time / effort in an attempt to reach an acceptable standard but to me, that's the best way to learn. (btw what IS bogging - sounds illegal out here! ) Chances are that the aforementioned will be redone when (if!) my skills have improved.