Managed to get a little bit more done on the car over the weekend, pretty much finished the left side and made a good start on the right!
And it all starts again on the right side
The right side required a bit more work to the left as it was all rusted out where the kick panel meets the inside piece of the A pillar.
You can see in the first pic here how thin it was when I went to clean the area to grind the welds off, wore holes straight through.
New patch panel ready to go in!
I didn't really get much time to do any serious work on the car this weekend
Got out on Sunday for a coupe of hours though and as my neighbour isn't home at the moment I figured it'd be perfect time to get the pot blaster out and clean all the area under the cowl so its ready for paint.
AFTER, I cleaned it up a bit more after these photos were taken, got rid of all the old sealant and cleaned a bit more of the paint and rust off. It was a bit of a messy job, but happy with outcome now that its done, now just have to finish up the repairs, paint it all and weld the panel back on
Finally a free weekend to get some more done on the car! Was hoping to get the cowl panel area finished, painted and back on but majorly underestimated the amount of work still to do and didn't even come close
I needed to replace all the steel along the front because of all the rust holes so I decided to do it in four sections. If I had have cut it out in one go it wouldn't have been supported and would have been a nightmare trying to weld it back up by myself.
The second section had the piece that had already been replaced previously, you can see in the pic the old weld weld was lapped and they didn't even bother welding it up on the sides
So for anyone wondering this is pretty much step by step of how i repaired this last section. I'm no expert so feel free to add any comments or ideas if you know of a better way of doing things
The main reason started this thread is because of everything I've learnt from others on here so just hoping i can ad something useful for others who are starting out.
I thought I'd taken more pics than this but first I started by clamping next to each plug weld and tacking it on the opposite side where the bits are getting butted together, you need to make sure the metal is tightly clamped together when when plug welding it together.
Then I just worked my way down clamping next to each and welding it up until I get to where I am in the picture below.
I also made sure the bits that were getting butt welded were nice and level with each other before tacking them.
You can see in the next picture that I've scratched the primer out a bit from were is going to be welded, although the weld through primer can be 'welded through' it just makes it heaps easier as it takes a bit to burn through the paint if you don't scratch some of it off.
Now that its all tacked its ready to stitch weld it up, this is done to try and stop the metal warping too much.
Pic below shows the first run of stitch welds, now this metal is a bit thicker than panels and it still warped a little bit when I welded it but is easy to tap it up from behind so I'm not too worried about it.
If this was a panel that was going to be seen then there's no way I'd weld this much at a time as I think it would warp too much.
Second run finishes off welding the patch in, now just have to grind them down a bit and clean it all up.
Is a good idea to look in behind the weld to see if there are any pin holes or bits you've missed, if there is you'll see the light coming through. Lucky for me I can't see any
I was clamping this nut on to weld in for where the heater vent screws into and ended up dropping it into the bottom part of the A pillar, anyway it had to come out as it was to big to fall out the bottom and last thing I wanted was a nut rattling around in while I was driving #-o
After walking around the shed for 5 minutes trying to find something to get it out end up wrapping masking tape over some electrical wire (sticky side out) and after stuffing aroung with my phone torch and the wire managed to get the nut back out \:D/
Next chance I get I'll be buying a little magnet in case it happens again!
Next was to cut out the last rust hole from under the cowl panel \:D/ . People have been asking me how I get the shape the for the patch panels I've made so far and picture two shows how wherever I can I'll try to use the piece I cut out as a template and make the new piece using the old piece as a guide.
You can see I basically just clamp the new metal to the old piece that I cut out and bend it around to fit. It never turns out perfect but at least it gets you close and just needs a bit of tweaking and trimming up to get it to fit.
About 4pm and had to call it quits at this point as housemates and neighbours were wanting me to pack up, would have worked all night if I could
Almost finished everything I need to get done before I paint it all and get the cowl panel back on!
Got about half the work done on the cowl panel so it will be ready to weld back on. First had to strip the paint and bog off it.
The area under the windscreen on the drivers side had been pushed in and was full of filler.
This is after I tapped it out and cleaned it up.
Made up a patch, welded it in and cleaned the whole lot up.
The left hand side is also going to need a new piece welded in.
Next pics just show replacing the bits that had rusted through on the front of the panel and cutting out the old repair job.
Decided to try and do something that was a bit quieter in the arvo so cleaned up the area under the cowl panel and gave it some coats of paint. I'm starting to get excited about welding the cowl panel back on and getting this area all finished :bounce2:
Managed to get a couple of hours done today, I've been really busy over the last couple of weeks which has made it hard to get anything done on the car.
Its good to see the weather getting better though
Sealed it all back up!
Did a few more repairs to the cowl panel, same as above.
Still have to fix it up in the corner part of the window channel, but it was too hard to get the right shape so I'll finish it off when its back on the car. There was just nothing to go off as it had all rusted away.
Pic one is before I tapped it back into shape.
Just have to cut out these last bits of rust along the window channel and it will be ready to put back on!
Couple more small repairs done.
Huge blob of brass had been used in a previous repair.
Also got this piece welded in but forgot to take a pic of it.