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  #31 (permalink)  
Old 09-03-2019, 04:43 PM
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I have pictures of this car when it was for sale in California in 1984. It had a louvered hood and was running bumper less. The pan covered everything under the frame so, until I got it off, I had no clue what was going on under it.
Not a show stopper by any means, I've fixed worse and had less to start with. I already have the frame sections available to me so they will get fixed right away.
Mark

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  #32 (permalink)  
Old 10-26-2019, 06:51 PM
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Haven't posted any updates in a while. I'll do some quick catch ups...
I think I'll be saving myself some money on this fender. This is after a couple of hours of dead blow hammer and off dollie work. I've got it to a point where the paint needs to come off so I can feel where the surface is. I am having the whole front clip media blasted next week. There is a lot to do yet but I think the fender will be usable with a couple more hours of hammer time and a lot of blocking...

Still lots to do but it is getting there... The paint has to come off though. I can't see or feel where the actual surface is because of the heavy layers of paint. I can tell it is close though.

Getting the outside straight took some time but it is very close right now.


Lots of work to do.
I'll be rebuilding the cowl bottoms on both sides as well as the inner structure.

I got the front fenders, inner fenders, inner hood latch and baffle, bumper brackets lower fender extensions back from the blaster.

The wrecked front fender is a piece of junk. The left is better but not by much. I'll get better pics of those while I am priming them.
The inners will need some work but are savable. Lots of straightening, hole welding and rust patching on both. I got those buried in black epoxy .
Yea... This corner was all bondo before blasting.

A little paint makes things all better?

See all the holes?

The hood brackets all came out looking like brand new! The blaster also does powder coating so he ran all of the smaller brackets thru his oven in satin black.



A little discouraged with the fenders. I'll give them a good looking at tomorrow while getting them primed...
Mark
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  #33 (permalink)  
Old 10-26-2019, 06:54 PM
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I've been working on smoothing the fender out a bit more and trimming off the lower part.
I worked on the fender for about an hour and this is what it's looking like now. Still a few highs and lows so I'll hit it with the D/A and some 100 grit paper to start fine tuning. I picked out a lot of low spots on this thing and took down some high spots, it was oil canning quite badly when I started but I have that eliminated now so I know it's very close.




I also trimmed off the bottom of the fender. Now I can work on the brace as well.

What a mess... Now, you have to realize this brace probably looks just like this ALL the way up the fender...

This is the piece I cut off with a hunk of the brace that was cut out.

The new lower fender will get trimmed to fit and I'll make a new chunk to fix the brace.


I cut the brow cap off and am glad I did. Lots of rust under there (as I expected) and it's going to be a job getting it put back together.

Sorry about the huge pics. I took these with my new phone. I will go back to the Mavica camera after this.

Lots of booger welds and braze.

After grinding off the welds and bits of cap that were left...
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  #34 (permalink)  
Old 10-26-2019, 06:56 PM
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This will get you caught up to last Thursday afternoon. It was a nice afternoon so I pushed the car outside and opened up the cowl areas...
Replacing both inner cowl panels and the non-existent rain channels is on the list now. Fabbing the new inners should be fairly simple after I get all of the rust cut out...
Passenger side.

Drivers side.

Fuse block...

HVAC box...


Some preliminary floor pics... The floor is a mess...


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  #35 (permalink)  
Old 10-26-2019, 07:00 PM
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Easy job to build the patch panels. These will be very straight forward. I can get good metal everywhere but, the firewall seam is the one that is rust heavy. I can get down to good metal though so doubling that seam up may happen to strengthen it.
I worked on the drivers side cowl today. I took the old cowl completely out, even along the top, which I had left on the other side. I will go back and take the rest out on the passenger side as well. It will make for a cleaner job.

What I cut out...

Cleaning up the rust on the inner panel.

I used a scrap of aluminum to protect the fuse box and wiring while I was cutting.



Doing a test fit of the new cowl outer. A "little" bit of trimming and this will pop right in.
I will blast these parts and bury them in epoxy primer before welding them in.
A little more cleanup work tomorrow and these will be ready to start putting back together.
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  #36 (permalink)  
Old 10-26-2019, 09:15 PM
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You're doing a great job on the front end.

Put the carpet back and drive the car after the front is done, or you won't be able to stop until you rebuild the tail light housings...
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  #37 (permalink)  
Old 10-27-2019, 09:57 AM
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cowl vents are designed to rust out and destroy our vehicles, worst design feature ever
just curious... haggarty didn't pay? or you just choosing to do the work yourself?
how was the haggarty experience?
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  #38 (permalink)  
Old 10-27-2019, 10:29 AM
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Quote:
Originally Posted by ogre View Post
cowl vents are designed to rust out and destroy our vehicles, worst design feature ever
just curious... haggarty didn't pay? or you just choosing to do the work yourself?
how was the haggarty experience?
Haggerty was fine. They paid to fix the "deer damage" and repaint the passenger side of the car. Doing the rust repair, fixing the frame horns and doing the floors and inner rockers is on me. No complaints at all with the insurance.
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  #39 (permalink)  
Old 10-27-2019, 05:12 PM
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Today I worked on getting both sides cleaned up some more. Cut more chunks out of the driver side at the lower door hinge reinforcement.
I will probably clean this up some more as I develope the patch.
Before doing a bit of trimming.

I was laying on the floor looking at this for 15 or 20 minutes... Using the angle grinder to trim out junk that will serve no purpose when the patch is welded in.

I came up with a plan to fill this hole. Tomorrow I'll start building the steel pieces. The passenger side will be similar.


I also got the rest of the old cowl cut out of the passenger side. A little bit of finagling and I got the new cowl panel set in place. This fits very well. From what I can tell the driver side will fit well also.



Still need to build the inner patch panels but those are very easy and not going to take much time at all. I should have this patched up this week.
Thanks for watching!
Mark
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  #40 (permalink)  
Old 11-01-2019, 08:12 PM
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A quick update. I marked up a pic with my plan. This repair will be done in four pieces. Let me know what you think.

The black and silver pieces I would like to do "one piece" but getting them in, behind the old steel is the trick.
1). Spot weld in the black piece.
2). Spot weld in the silver piece.
3). Spot weld in the red piece.
4). Spot weld in the blue piece.
Prior to welding, all of this stuff will get buried in epoxy primer. After welding it will get rust converter and then more primer.
I am thinking about popping a 2" hole in the lower A pillar, under the fender just for ease of access after it is rewelded. I will probably do the same on the new outer cowl before it gets welded in just for access after it is welded on.
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  #41 (permalink)  
Old 11-01-2019, 08:14 PM
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Got the patch panels made for the lower A Piller hinge reinforcement.
I'll do some adjusting of the fit before these get welded in. There are two more plates to make. One that will weld to the left hand wall and another that covers the nut plate.
The upper (black) piece.

The lower (silver) piece.

Fitting the top piece.

Fitting the bottom piece.

Pulling everything together with screws and clecos.


Thanks for watching.
Mark
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  #42 (permalink)  
Old 11-01-2019, 08:19 PM
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Making more progress. I got the "red" piece made along with a smaller "gap filler" to strengthen the gap between the new piece and the original steel on the side of the cowl.

This one will get some plug welding holes punched into it and be ready to go.


I also got a good start on the inner cowl patch. I cut a piece of 16ga to fit the upper opening and put a roll on it to match the curve of the cowl. It's amazing what a block of wood and a dead blow hammer can do in 10 minutes...

The curve developed pretty quickly using the dead blow hammer.

It was getting close at this point.



A little more tweaking and it will be good.

Fits like a glove! I'm pretty happy with this piece. It will plug weld in nicely.

I will get the bottom halve of this patch made tomorrow and This will be ready to prep and weld!
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  #43 (permalink)  
Old 11-01-2019, 08:21 PM
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Spent more time taking out useless metal. I stripped out the leftover flange from the inner cowl, the piece I am replacing. Now all that is left is the firewall flange so, with the patches I am putting in and the new outer cowl panel the thickness will be back to three layers which is what it should be.
The cleaned off firewall flange.

Surprisingly this is pretty solid. The new pieces will weld to this just fine.
Making the inner patch. I bent this flange to fit over the firewall flange. Dead blow hammer comes to the rescue again!


I'll get out the shrinker/stretcher to roll this flange to match the cowl.


Punching some 1/4" holes for plug welding and getting all of the joints cleaned up is next on the list. Getting this welded up will be a big step.

Next on the list is the drain channels....
Mark
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  #44 (permalink)  
Old 11-01-2019, 08:23 PM
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I have the left hand side panels ready to weld in. Finished up this piece and worked on fitment. Got everything fitting pretty sweet so I pulled it all out and punched and drilled the plug welding holes. Ran the flap disc over a lot of the mating surfaces to clean things up a bit more but I think it's as ready as it will ever be.
Now, on to the passenger side tomorrow!
This is the fit of the side piece under the cowl top piece. Took three hits with the shrinker die to pull this around.


Worked on fitment.

After drilling and punching the plug weld holes.


Nice tight fit all around. This should weld up beautifully. I made a small patch for that gap in the back. it will get welded in when I do the rest of the parts.




I'll get to work on the other side in the morning!
Thanks for watching!
Mark
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  #45 (permalink)  
Old 11-01-2019, 08:54 PM
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Excellent workmanship ! That will make a very nice, and safe repair.
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