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View redsdad's profile Entries: 543
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05-03-2011 10:07 PM Battery Box Ready to Weld In
Ground down all the rosettes tonight. Started cleaning flange of opening. There are rust pits. Need to decide if I am going to acid or sand blast.


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  [Entry #358]

04-30-2011 03:18 PM Start of the Finish of the Battery Box
The end pieces still needed the rosette holes. Seven each end for a total of 14. They ate my lunch and my drill bits. Stainless steel is hard on bits.

There also needed to be 4 rosettes for the Dzus brackets, 2 stainless, 2 carbon steel.

Anyway, got all 18 holes drilled. The Dzus brackets are installed. Once all the rosettes are ground, the box will be ready to go in.


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  [Entry #357]

04-24-2011 06:23 AM Battery Box
I wasn't satisfied with the lid. It was too small. So, I made another one. Too big! Made a third one. A little small, but bigger than the first. I still had to add "corners" to the inside of the box so the gasket will seal, but it was better than the first one.

I need to weld in the Dzus brackets and grind all the rosettes smooth. After that, the box will be ready to weld in the car.


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  [Entry #356]

04-24-2011 06:19 AM More Trunk Welding
After massaging the right side of the roll pan, the angle piece was fitted and welded in place. Since it looks like the left side, there are no photos.

There was a large hole left from the removal of the spare tire holder. While looking at it, it became apparent there was also a hole at the other weld which was cut. A replacement piece was cut for the large hole and both holes were welded shut.

The battery box needs to be welded in. I want to at least cap the openings where the seat belt reliefs were cut. And, I need to weld lack of penetration areas from underneath. Not all that much left to do on the trunk area.


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  [Entry #355]

04-17-2011 10:23 PM Trunk Floor Extension
The angle piece was welded in on the driver's side. Can't get the grinder in there to finish the welds. No one will see them anyway.

The passenger side was a different story. After the opening was increased by a saw kerf width, the stretcher was used on the angle section to make it fit. When it required much more curve than the driver's side, it was obvious something was not right. The passenger side had a much larger "dip" in it. Instead of welding in the angle, the rest of the day was spent moving it out to match the driver's side.


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  [Entry #354]

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