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Monday, May 17, 2010

A nip here, and a tuck there

So now that the rusty bits are out of the way, the chassis resembles clean metal panels in most places and swiss cheese in the majority of others.

Because no one likes a cheesy car, my next task is to repair and/or replace the parts that most resemble lace or an old log ravished by termites.

Simply because it is the more accessible side at the moment, I am working around the car, clockwise, starting at the front passenger wheel well.  Areas addressed so far include:

  1. Rust damage at fire wall / rocker panel area - expected damage type and area
  2. Stress Fracture at stiffener brace - evidence of frame stress
  3. Stripped out / dented brace connection point - repair needed for proper re-attachment of brace
  4. Bent / Warped vent flaps - due to buckling of front corner
  5. Bent / warped tow point area - due in part to improper jacking, but it turns out the worst damage is due to this whole corner being pushed back approx. 1/2" (presumably in a past wreck - this would be consistent with damage to the driver side fiberglass, radiator damage, and stress fracture (#2 above)).
  6. Bowed out / disconnected panel - also due to the pushed-in corner.









1.  Rusted metal removed and prepped for patch work

2.  Cracked area welded shut





















3.  Brace mount area re-shaped.  (I still need to weld a flat washer over the hole to restore the structural capacity.)
4.  Vent fins straightened / repositioned
5.  Bottom corner brace beat back into place and sheet metal flattened.
6.  Repositioning of the corner corrected most of the bow in the side panel.  Panel tack welded back into place along the length of the panel.

What at first looked to be mostly cosmetic repair turned out to largely require structural repairs to the main front channel frame.  As seen below, the bottom right corner is particularly buggered, and required beating back into place.


This is what it looks like after a lot of straightening. Note that although the worst damage was on the passenger side, it was enough force to tear the channel on the driver side, requiring a welding repair.

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