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.
It was a short day. I went back to the swap meet this morning. Bought a SKIL palm sander for $5. I think the deal of the meet was probably a 70 or 71 El Camino. A little rough, but the neighborhood nuisance sticker indicated the owner was eager to sell. Marked down from $350 to $325.
The second side always goes better than the first. I changed the angle of the cut from being parallel to the side to being perpendicular to the bottom. I also used the Dremel tool with the 409 cut-off wheel (actually went through 4 of them) to cut the horn recess. I find the 409 makes a perfect kerf for MIG welding sheet metal. So far it went together a lot easier than the other side. It should test fit and finish on Tuesday.
The usual drill. Add rosette weld holes. Weld through primer.
Then the chin was mocked up and the rosettes were put in.
After adding a couple of fillet welds along the side and end of the support, and a lot of grinding, the chin went back of a test fit.
It all fits. The supports must have move a little on welding. I am hoping a little persuasion with a hammer will loosen things up. If not, cut and move. I really don't want to do that.
The panel is in. Both the inner fender and the horn baffle still needs the triangle piece to fill the gap between the two angles. And some of the bolt holes will need opened up. But it is getting there. I will move to the right panel next. Hopefully I can get it done tomorrow.
The swap meet was big. I was surprised how many vendors. Bought a fan. May go back tomorrow to see if any new stuff shows up on Saturday.
I decided I needed to get the chin to fit before I went on with the horn baffles. There are two support angles than attach to the radiator core support. These will have to be moved before the chin will fit.
The speed nut also needs to move 3/4". I decided the the best way to do it was to move the tab. A 3/4" section was cut out the the tab with the speed nut moved.