Small fillers were cut to "cap" the top where the flange was pulled away from the core support at the top.
After a lot of welding and grinding, the core support will need just a thin skim coat to look like it was stamped this way.
A final check with the radiator to assure it still fits. I also test fit the 16" thin fan I got at the swap meet. My initial thought was to mount it low and put twin 7 inch units at the top. Problem is, even with the thin fan, I will have to move the engine back. That means firewall modifications. I am not leaning toward mounting the 16" puller high (it will fit that way without moving the engine back) and putting a 16" pusher low in front of the condenser. I guess if it were easy, everyone would do it.
So, until I get the condenser, the core support has reached a stopping point. I hope to have the condenser by next weekend.
It was cold and wet today. I think it was 56 when I went out and 58 when I came back in.
While the left side had basically the same size triangles, the left side was larger for the horn baffle but smaller for the inner fender. Strange. Thing is, they all look basically the same. Must have been the way they were cut and bent.
The triangles were tacked in place on the car and then taken to the bench to finish welding and grinding.
Now that both inner fenders and both horn baffles are welded, I turned my attention to the radiator support for finishing. The first thing I did was weld up the not-through cut I made on both side which facilitated bending.
I thought I could get both sides done tonight. Got the driver's side done. Didn't even start the passenger side.
Filler triangles were cut from some scrap. I tacked them in place on the car and then finished them up on the workbench. After some grinding, they are ready to de-rust, prime, skim, and finish. That will come much later. On to the passenger side. Weather permitting, Saturday.
Finished grinding the weld proud and filled the three holes tonight. The ripped bottom of the slot where the horn baffle bolts to the chin was repaired.
I am really getting an education as to the best way to bolt these parts together. A few more times and I should be able to put the painted versions together in my sleep. The baffle was bolted to the core support first. You can see where the triangle shaped pieces still need to be cut and welded in. This should be completed by the weekend.
This baffle, just like the other side, still requires the triangle filler, a little bit more grinding, and a skim coat of bondo and it will be better than new. And, I think it will be difficult to distinguish it from a stocker.
I am not sure if you can see it in the final photo. The stock chin has a longer "space" between it and the core support. Almost like Chevy knew the AC condenser and tranny cooler lines would be running through there. Time will tell if the 1941 engineers allowed enough room for all four lines.