Cary's 73 1.7 Rustoration Thread Options

[cary]

So I begin to fit the passenger long .................





Not liking the fit to our original get it on the road repairs 10 years ago.

[cary]

Needed to reduce the long opening about 3/8 of an inch.
Easy deal ................claps did the job.








So begin I to cut out the corner ...........

[cary]

So here's where we left off.



We spent most of the afternoon forming the new corner.
Didn't take any pictures. (IMG:style_emoticons/default/sad.gif) (IMG:style_emoticons/default/sad.gif)

[cary]

Next time I'm going to strip the entire car first .................

But this started as a while your in there project............... Lesson learned.

Might have to start saving for the small Dustless Blaster.

[jimkelly]

it does seem that a stripped and sand blasted tub is the best way to begin.

I have to say, this is one of the most metal-removed long/hell hole repairs in recent memory.

(IMG:style_emoticons/default/beerchug.gif)

[cary]

Back to work ....................
I'm going to go to work on the inner box for the drivers side.

Went back in and reread Jeff Hail's Dead thread.



Finally using my Hot Spot at the shop.

[cary]

Reworking a few of the patch seam welds on the long.

Practice, practice, practice.

[cary]

Decided that I needed to cut off the lip.
Just couldn't get it to fit with the lip attached.

[cary]

So I decided to cut the holes in inner box.





Free-Handed I'll have to come up with come sort of jig gadget.

[cary]

Time for lunch ................... Off to Subway

[cary]

Back to work on the inner box on the drivers long.
My welding is getting much better. Almost know what I 'm doing on good metal.



Weld thru primer sprayed on. Rosette holes drilled.



Didn't like the self taping screw technique this time. The hole on the old long needed to be bigger. There was no where to start the weld on the new metal inner box.
So welded from both sides. (IMG:style_emoticons/default/sad.gif)



Now ready for seam sealer and primer ..................

Had a good day. Super In Law made good progress on the right side front inner fender .... Didn't shoot any pictures.

[cary]

A month has passed since we've accomplished much. Yesterday was a good day.
I'm working on the extending the outer drivers wheelhouse that was removed due to the cars medical condition. (IMG:style_emoticons/default/sad.gif)

So I start with making a cardboard pattern.



Here's where I'm working.



See that little magnetic light. Way cool. Bought it at Bi Mart here in Oregon. It has improved my welding about 100%. $13. When I get a chance I'll post the manufacturer info so it can be Googled.

Tool Whore bought a second one. I just leave it attached to the welder. Easy to find that way.

[cary]

Here's the completed extension.
Being that its the drivers side, no RD parts available. I know, most smart people would have walked away.



Here it is test fitted.

[cary]

Tool Whore side note :

Built another jack stand so I could get the lift arm out of the way.
Ducking in and around that thing puts me in a poor mood.
Man, I want to get this thing off the lift.

I think I'm going build the jig Jeff Hail built for the next one.



Don't worry, that is jack point #8. It's not going anywhere.

[cary]

Super In Law is working on the other end.
The inner fender that the front of the long attaches to. Both sides of the this car had the disease real bad. So this repair is more about strength and function.
I'm building this car to be my daily driver when finished. Rain, sleet or snow.
Oh yeah, we're going to call it Icicle to match my white and blue Carrera.

We'd already done one patch. But it didn't align with the new outer long. (IMG:style_emoticons/default/sad.gif)
So we cut into it again and added another patch. Not exactly they way you'd want to do it on a customers car.
I don't imagine anyone else we be where we are. But its something to look out for.



Still struggling with welding old metal to new. But we're getting it. Zig zaging really helps. Then not being a dumb ass and take your finger off the trigger. LOL.

[cary]

Here's the fit we're working on.
Plus keeping the door gap at a perfect 5mm.



Seam sealer and under coat will make the less than stellar patch disappear like magic.
But I'll know its there. (IMG:style_emoticons/default/sad.gif) (IMG:style_emoticons/default/sad.gif)

[cary]

Here's the test fit at the end of the day. (IMG:style_emoticons/default/biggrin.gif) (IMG:style_emoticons/default/biggrin.gif)

[cary]

Prepped the heater tubes for installation.

Next step is to encapsulate the inside. Finish up welding on the patch on the heater tube corner in the engine compartment. Get that all sanitary and seam sealed before the heater tube is tacked in.

[FourBlades]

Awesome thread man!

You are really getting there.

I always found using the bzzt bzzt bzzt technique of just making one large tack weld after another to be the easiest way to deal with the old metal on these cars. You start the next tack weld while the previous one is still red hot. Putting the next tack on the edge of the red hot one prevents any problems getting the arc going cleanly.

It ends up looking like this. This was tacked at 3 inch intervals all the way around and then filled in slowly.



Looking forward to seeing your car back on its wheels again.

John

[cary]

Nice work. Thanks for the tip.