More updates, there is an insane amount of hours being spent on this piece of crap to get it to a reasonable state for painting. You'll go through the update in minutes but there is literally days of work in the photos.... everything from picking up supplies, repairing replacement sections, fabricating bits and pieces etc etc.... it all adds up very fast. I sometimes look at what's being accomplished at the end of a day with not much visual difference even though I've been busy working on a section the entire day.
Pic 1 modifying the inner quarter to fit the sedan skin. They are slightly different, which I didnt know before. If there is a next time I'll just use the spare coupe quarters I have ! Pic 2 blasted prior to priming.
Primed in Pic 1, Pic 2, finishing off the wheel tub fabrication/ repair.
Finished and seam sealed, waiting to prime again. Pic 2 skin, stripped and primed prior to welding.
Plug welds done, Pic 2 shot from inside the wheel tub which was repaired (rusted from inside boot between skins)
All primed and welds seam sealed.
Marking out and cleaning plug weld areas for lower skin join.
Tacking/ welding new skin in place.
Welding pretty much done.... not too shabby
Plug welding along bottom of skin.... Pic 2, got side tracked and started finishing off doors as I wants to paint the door shells for a bit of motivation.
Doors got a smear of filler to smooth out a couple of things that I couldnt get rid of without removing the door skin from the shell, this is taking long enough without going to thoses extremes ! Doors are ready from blocking then priming then paint. Its tedious to get everything spot on.
Couple of shots of the finished skin repair ready for a little filler, then priming.
.........and that is all this time around. Shell is almost done, a few small things here and there to be done. Main things are finishing off the left quarter + repairing the beaver panel then the shell will be almost ready for paint preparation. Unfortunately its all the small things that consume the most time. Gearbox is done, will be dumby fitted shortly. Im getting the engine ready for its rebuild shortly.
Here are a few more...
Marking out LHS door mirror holes using a template from RHS. Pic 2 sorting through duplicate stainless trims that sit above door and rear quarter window.
Pic 1, they have all seen better days, lots of scratches and a few dents here and there. Pic 2, I had to go down to MazBitz to pick up some parts, since I was going there I saw it as a good opportunity to get some of the smaller side jobs completed. Rick did a fantastic job, mirror shine + no dents = one happy customer
Another pic of Rick's work.... great result and another step finished in the overall scheme. This is a dying trade unfortunately for us restorers. They are impossible to photograph because they are so shiny. Best I could do was with the flash tuned off. Pic 2 Fixing the RHS quarter window rubber holder. If you recall I had to do the left side as well. This outer holder is rusted out. I made one using a swage and jenny some time ago but had misplaced it. Unfortunately I didnt have a access to swage machine this time around so had to be a little more resourceful. Marking out the shallow S shape on a bit of thick ply for my hammer form. I found the inner panel I made a couple of years ago so that bit was easy. (part at the top of Pic 2)
Pic 1, ply cut to shape, Pic 2 metal that will make rubber holder screwed into place for hammer forming with chisel and hammer.
Hammer and chisel gradually give me the recess Im after. Pic 2, checjing out the rubber gap with outer and inner panels clamped together. Silicon glue is out of the question to hold rubbers in place!
Screwing one of the fabricated parts into place for cutting. Alot of work for something that will no be seen.
Welding into place...........
Turned out OK, still need to finish cleaning welds up then will do my filler work. Took about 15 minutes to make. Pic 2, if you recall from earlier in my build the car had scrapped a wall at some stage and malformed the wheel arch. I also had to cut the lower section of the LHS quarter to fit up the new sill panel. Here is the replacement section, I've tapped alot of it straight but still a long way to go. The amount of body filler below the crease line is freakin unbelievable !
I will completely discard the metal area below the crease line and fabricate one piece of metal from there down (thats the plan at least !). This will be done off the car. Pic 2 Im also fabricating the outer wheel arch for the replacement area. The area below the crease is a well known rust spot in coupes, not uncommon to find lots of fibreglass and bog down there. Yes I hear you, why bother...because Im more than capable and can.... it wouldnt be a resto otherwise and you'd be reading the same boring sh!t as everywhere else
Im trying to tidy up a few small jobs as the shell body work is drawing to a close. I bought this stuff from RareSpares. Rather than use Mazda's genuine plastic coated metal clips I decided to use repro Mitsubishi Sigma clips as these cant rust under the stainless trims. They seem to fit just right as well. They cost approx .70c each as opposed to Mazda charging me roughly $5 a piece. Multiply that x 36 clips and that equates to a bit of money. The part number is on the brown bag by the way. Pic 2, I need to grind off some of the clip studs that hold the stainless trims in place to finish off the body work around the front windscreen seat. They needed to come off to finish off the shape where the A pillars were repaired. I cant sand the repaired area with the studs in place. $8.50 for 15, part number on box. These are NOT standard rivets if you take a close look.
AND finally I picked up my reco'd 5 speed from SelectMaz. Issy who has years and years of experience organised to have syncros, bearings and shift forks replaced/ fixed as necessary. Im using a Rx5 extension housing and RX4 twin dizzy large starter hole bell housing to match it up the 10a engine. The gear cluster casing is 121/rx5. We turfed the TQX idea as it was a headache changing all the shift rods to make it work with the Rx5 extension housing. No 4 speed for this car as it'll be racking up lots of highway Km's. Extension housing will have paint blasted off prior to fitting. Pic 2, Rick from Mazbitz let me loose with some power tools in his shop. I salvaged 2 boot/ beaver bumper brackets as one of mine was bent from a rear hit to the right. Both these guys are very helpful, friendly as has everyone who I have chosen to use