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Topic Review (Newest First)
01-14-2020 04:56 AM
astroracer Thank you sir! I am humbled by your comment!
And thanks for the welding rod idea, I have a bunch and never thought to try it for this. I will definitely give it a shot. Right now I use the hot "BB" on the end of the wire. It is usually hot enough I can use it, as you mention to use the welding rod, as a filler to build up the blown out area. usually a few quick pulses with the BB's, shoving them into the hole, will build it up enough to take a full pull when the machine is set on spot. You really have to watch the parent metal though. In some cases it just won't take the heat...

Got home from work last night and beelined it straight out to the shop. Had a plan and stuck to it. Made a quick template for the floor patch out of card stock and set up the bead roller to tip the flange.
Didn't take any pics until the template was done and I had started on the patch itself.


Running the piece thru the tipping dies. This is 16ga so I could only tip it so far and the nylon roller didn't like the pressure.



I ended up finishing the bend on my metal bench. I also had to stretch the flanged edge a bit to bring the panel back to flat.

With the flange mostly done and the piece clecoed in.

Looking back at the patch from the front tire... I outlined the hole in the floor because I will trim the patch a 1/2" oversize and flange the edges to drop it flush with the toe board on the outside.

I will need to do some tweaking on the flange but I can wait and do that after the piece is welded in.
I also started developing the inner A pillar reinforcement patch.

This will weld between the outer and inner rockers. I won't do much with this other then get an oversize piece trimmed out.

I can't fit it to the car until the outer is replaced and lower A pillar rebuilt.
Thanks for watching!
Mark
01-13-2020 09:34 PM
Too Many Projects I have used an old trick for those thin areas that keep blowing out. If you have some old arc welding rod around, 6011, 6013, knock the flux off and hold the end in the blow hole, or right next to it, if it doesn't fit and melt it in with the trigger pull on the mig. It will help fill faster and minimize the blow out.

That car is lucky it found it's way to you...
01-13-2020 09:53 AM
astroracer Looking at the rocker after I got the brace out of the way... You can see the upper rocker is very cratered and thin. The floor flange is all but gone and the A pillar reinforcement is pretty much non-existent.

After I got all of the rot removed. The outer had been replaced at some point, with a cap. The old outer is still there and it all needs to come out.

I worked through a bunch of "fixing it" scenarios in my head and the best one was to simply replace the entire rocker. This side I can justify doing that as the entire top of the rocker has issues.
The new piece won't be here until Friday but I have plenty to do in building patch panels for the lower pillar, the inside rocker reinforcement and a section of floor I removed as it was all holey and thin.
Here are a few pics as I was getting things gutted...

Looking back, down the length of the rocker. You can see some warping in the top of the rocker as it compares to the bottom of the door. There is some stuff going on there that I want to fix. I will try to get pics of it tonight.

Here is a shot of the section of toe board I removed.

I'll get busy fabbing the patch for this and the inner rocker/A pillar reinforcement tonight.
01-13-2020 09:50 AM
astroracer Yea, the passenger side was usable but the drivers side is shot. I just ordered a complete outer for that.
I got all of the junk cleaned out of the rocker and footwell yesterday. I cut out the footwell and the front floor brace came with it. It was not attached to the rocker at all. Once the body mount bolt was out the whole piece was free.

I separated the brace from what was left of the floor and cleaned it up. Luckily it is in real good shape and reusable!

After some scraping, a little grinding and some wire wheel time we have a clean brave. I still need to spend some time on the inside de-rusting.

The outside looks pretty good as is. There are no thin spots so this is good to go.
01-13-2020 09:47 AM
astroracer I have the passenger side complete now, other then smoothing down some of the welds and getting the worked areas prepped, painted and sealed up. I won't do any of that until the drivers side is in.
I started looking at the drivers side the other night to start cutting it out but I decided to do some A pillar work before I remove the floor. I think it's a good idea to get this area rebuilt 1st.

I started cleaning it up, looking for the spot welds. I'll get some pics later as I start digging into it.

Most of the wiring channel on this side is pretty good and the area in front of the rear wheel well is still solid so I don't think there will be as much work replacing metal as there was on the other side.

Looking back at the passenger side... There just wasn't much left.

Thanks for watching guys!
If there are any suggestions or guidance concerning rebuilding the lower A pillar, I am all ears!
mark
01-13-2020 09:45 AM
astroracer Anyone interested in an update?
Like we've been talking about I welded the two pieces of the inner fender patch together. I and got all of the plug welding holes punched and drilled.
The visible side.

The inside.

The drilled holes. I opened these up to 1/4" after I took the pic. I also drilled holes in the two flanges to weld from behind.

After a bit of cleanup with a wire wheel the welding went fairly well except for two spots at the top of the patch. I quit chasing the holes as all they were doing was getting bigger.

I may work on these tomorrow. I need to get a copper backup spoon on the inside but that takes two... I am only one. I'll probably just paint and seam seal them up...
Once this is painted and sealed up I think it will look great!
Thanks for watching!
Mark
01-05-2020 08:34 PM
astroracer My thoughts as well.. Weld it up, it'll be done. This will get treated, painted and seam sealed when it's done so it should be fairly rust free for a long time...
Mark
01-05-2020 07:08 PM
idrivejunk I wouldn't remake the whole piece, just butt the pieces together. Any layering that can be avoided means better corrosion resistance. But! That would be fine in that spot if its what you would rather do since its ready. Done trumps perfect more often than not and you have made good choices so far.
01-05-2020 06:52 PM
astroracer Getting closer to wrapping up the passenger side. Both floor braces are in and I have the inner fender patch and some rocker "finishing" pieces fabbed up.
Lots of work to get the braces to fit right. Snuggling up to the floor and inner rocker required two cuts on the rear brace and one on the front seat brace. Spent all day saturday getting those done and the front brace welded in. This morning I got the rear brace finished up and welded in as well.



Rear brace work.



This is the inner fender patch. It is two pieces right now just because I changed my mind on how I trimmed out the old tin. I am debating remaking this in one piece but I don't know what that will really gain me... Thoughts? Other then less welding? As it is this will get welded together before it goes in...

Thanks for watching!
Mark
12-30-2019 06:20 PM
astroracer The floor is in, the rockers are in and the door still opens and closes!

The outer rocker is welded on. It's not pretty but it will do the job with a little bit of filler. Trying to weld to the old thin fender was a real ******...

The floor is so solid now it's like a new car!


I will knock down the welds a bit tomorrow and get some primer on them. The rear fender patch and front floor brace still need to go in but these are cake now that the big piece is permanent.
Thanks to everyone who helped with pictures and advice!
NOW... On to the driver side...
Mark
12-27-2019 07:27 PM
astroracer One day closer!
The new floor channel is in.


The old floor is trimmed, cleaned and prepped for welding.


The new floor is "just about" ready to weld in. All of the plug welding holes are punched or drilled and I am working on getting the seat braces installed.


I have a bit of work to do on the inner rocker but that won't take long at all, I should be welding this thing in tomorrow!
Thanks for watching and for the help!
Mark
12-26-2019 05:19 PM
astroracer Big day today! I started welding!
The new rocker weld flange is part of the rocker now and the door jamb repair is welded in.


The jamb patch as welded. This is ugly but there is enough weld there to grind it down for a smooth transition.

After some clean up with a cut off wheel.

A little work with a sanding disc and this will be ready to prime.
I also got the new J channel fit in and trimmed.

I drilled the rest of the rivet holes in the side wall and finished cleaning that up. A heavy coat of rust converter and some primer and this will be ready to go together.

I got the top of the center brace cleaned up and the whole thing buried in rust converter.

I will have to install the floor one more time to mark the edges of the floor braces so I can drill plug welding holes.
I will trim off the excess tunnel material tomorrow and get that and the foot well cleaned up for welding. The seat riser is ready to go so getting the tunnel and foot well ready is the last step for prep.

This should come together pretty quickly once the new J channel is installed.
Thanks for all of the help guys!
Mark
12-26-2019 08:24 AM
astroracer I built a small doubler to close off the end of the rocker before my fender well patch goes on. This is it being made, I guess I didn't get any pics with it in place, I'll do that today.
This will weld between the inner rocker, bottom of the outer rocker and bottom of the new J channel.


I also got the inner fender patch pretty well complete. I am debating cutting off the rest of the original inner fender (along the top) and making this all one piece, it would clean up that flange a lot and make it all one shape.




Started fitting the rear brace splice. Lots of work in this one.

I had to slice the channel to get it to snuggle up to the rocker AND fit up to the floor. This will get welded solid with a doubler on the inside.

There is still a gap at the flange to floor area so I am going to cut the sides from the floor (dashed line in pic) of the brace to allow the flanges to come up higher then I will weld the gap.


I am also going to fab up new inner rocker braces that weld in just behind the center brace.

This one was pretty rusty but it was still intact enough to flatten it to make a pattern.


I will make two of these when I do it. I am sure the driver side piece is shot as well...
Thanks guys! Hope you had a good Christmas!
Mark
12-26-2019 08:20 AM
astroracer I got this repair mostly fleshed out Tuesday.
The new jamb patch is screwed in place, the outer rocker is screwed in place and everything lines up very nicely at the inner rockers lower flange. I have a few more things to work on but I should be able to start welding this together.
Here's a few pics of what I got done today.








Mark
12-26-2019 08:18 AM
astroracer Thanks IDJ! This is kind of fun, I do enjoy the design and fab work.
A little bit of catch up...
I have all of my repair parts on hand. The rear brace repair pieces were delivered the day before Christams so now I am not going to be waiting on parts to get this done.
These are the repair ends that came in.

This is what was left of the passenger side brace. I trimmed off both sides to make room for working on the rockers.

The new brace will get opened up to slip over and weld to the original.
I spent the whole day today cutting up the rocker, removing old patches and trimming back the rust to good metal.

The rocker had been "repaired" at least once before. There was almost a half inch of mud where they had beat the rocker in for some reason.

There was also a bad repair in the door jamb corner so that got cut out as well. This is a first take on fabbing a patch. Learned a bit doing this and will remake it to cover more and fill that triangle in.

I also got the new rocker piece cut up. I trimmed off the upper half, which I don't need and had to do a lot of reshaping to get the profile to match what is on the car.

Did some experimenting with patches. This piece will weld to the bottom of the sill. It will carry the rocker patch and help strengthen the rocker that I have pretty much cut in half...


I will put the floor and inner rocker back in to set the height for the new rocker outer to weld to so it is positioned correctly.
There is a lot of work to do here. I think I got a pretty good start.
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