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> Cary's 73 1.7 Rustoration Thread
nathansnathan
post Dec 15 2013, 06:23 PM
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It's a lot of work to make not only the inner forward of the firewall with the relief for the floor, but the outer rear of the fw is a real pain with the engine shelf cut out and the radius, the bend, etc.

You might want to do it the way Jeff Hail did, kind of an in-between way, the corrugated piece stays on the outside. It would help to add the top and bottom to the inner that the template is representing there, 3-dimensionalize it for strength, like the factory, but not as elaborately shaped. Seems like He should have brought it forward more to double layer where the lower seatbelt nut is
(IMG:http://www.914world.com/bbs2/uploads/post-7712-1193013473.jpg)
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cary
post Dec 15 2013, 08:10 PM
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As I reread your thread about 3 times I'll have to ponder.
http://www.914world.com/bbs2/index.php?sho...3507&st=150
My original plan was to follow Jeff's example. Now you and Scotty have given me a couple more ideas.

I really don't want to weld on those ribs .............
I don't like the void that would be created by using a flat plate. Granted mine will be painted. Unlike they way we came from the factory. hmmm.

But you, Scotty and Jeff do beautiful and great work.
I do thinks its pretty cool that you recreated the factory part. I think if ever have to go this deep again. That's the route I'll go. Build it all on the bench.
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cary
post Dec 17 2013, 08:00 AM
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I'll be getting the contact info on the PDX Wurth Rep so I can buy a spray on seam sealer gun.
Running back thru Jeff Hail's Dead thread. It just looks right, and tidy.
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cary
post Dec 20 2013, 07:56 AM
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Still chilly in PDX. 32 degrees when I made it to the shop at 9:15.
Decided to put on my big boy pants and cut the door post.

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BEFORE

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AFTER

That will have to be cut in order to slide the inner rocker in place. Dumbass, I shouldn't have bothered seam sealing it.
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cary
post Dec 20 2013, 08:17 AM
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I went ahead and added to the inner portion of the wheelhouse extension.
Might be a bit too long ...................
Plasma cutter will make short work of it if need be.

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Learned today I need to do a better job of making sure the pieces are perfectly flat before I weld them. That way I won't end up with the craters on the outer edge. (IMG:style_emoticons/default/mad.gif)

Then I test fit the outer wheelhouse extension over the inner. A little long on the top .............
Bottom right corner needs a little hammer work too.

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End of the day shot ...............ready for a week and half's vacation starting Christmas day.
Hope to have it off the lift with the floor pans installed.

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Now I start the Five Day Marathon of running a supermarket up till closing at 7pm Christmas Eve ................ I'll be back next Thursday .........



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cary
post Dec 27 2013, 10:24 PM
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On we go .............it's a little chilly in my non heated shop. 34 degrees and frozen fog.
Insulated boots and overalls.

Started with finishing up the left outer wheelhouse.

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cary
post Dec 27 2013, 10:29 PM
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Then we dug into the left hinge post and fender support.

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Trying to figure how to patch the upper hole without removing the fender.
Sprayed down with Ospho

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cary
post Dec 27 2013, 10:33 PM
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Then went on to installing the right front inner fender corner.

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Welding is getting smoother and smoother.
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cary
post Dec 28 2013, 10:00 PM
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Tool Whore Comment :

First time I've used the reinforced cut off wheel for the Dremel. Impressive.
So I bought a couple refills.
Works great when you want to peel back a double layered section.

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The brown thin ones are a POS. I usually cant make it from the bench to the car without breaking one.
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cary
post Dec 28 2013, 10:05 PM
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Decided it was time to build up the right long. So I need to tidy up the heater pipes.

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Time to use the blast cabinet. Just finished giving it a tune up. New hose, nozzles and shield.

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cary
post Dec 28 2013, 10:13 PM
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So I begin to prep the long. Come to find out the hole in the new long is 2". The heater pipe in 2 3/8". Dandy ..............

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So time to hook up the plasma cutter. Getting a little better at setting it up and free handing it.

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After a coat of primer. It's time for a couple coats of Rustoleum.

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cary
post Dec 28 2013, 10:28 PM
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Pipes all primered and painted with Rustoleum.

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Long all built up and ready to install. Make sure you install the heater pipe before you mount the long.

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Spent the rest of the day adjusting the left outer rocker position. I had to relocate the position I'd been using. Couldn't get the bottom of the hinge post lined up.
All in all, a good day. By myself, radios blasting the 70's & 80's station, and a pot of hot coffee.
A little chilly. But spent most of the time in the wood stove heated space.
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cary
post Dec 29 2013, 09:40 PM
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Still chilly and foggy.

Time to create a pattern to extend the hinge post that I'd already prepped. I cut out some cancer inside the left front fender. I used the Ed from Wheeler Dealer tape pattern technique.

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Worked pretty good. Should have cut the pattern inside the lines.



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cary
post Dec 29 2013, 09:48 PM
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Spent quite a bit of time fiddling with the fit. Had a tough time creating the rounded out of site corner. Once I had it trimmed and fitted it was time to cut the bottom off so the inner rocker panel can be installed.

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cary
post Dec 29 2013, 09:55 PM
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Ended the day with tacking in the hinge post base. Tough duty welding material that can't be totally prepped. Backside

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Spent the am working on the middle kids Explorer. New alternator, fuel filer, oil change, new wipers, and polish the headlight lenses.

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cary
post Jan 1 2014, 10:59 AM
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Big Day planned for New Years Day.
Going to install the right drivers long. Maybe get the wheel house and firewall tied in.

Finished up the left front fender inner patches yesterday.
Left the phone laying on the desk

Off we go ................
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cary
post Jan 1 2014, 01:40 PM
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Here's yesterday's repair. Making those little patches is a lot of fiddling..............

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cary
post Jan 1 2014, 01:59 PM
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Heading for the next point of no return. Attaching the right long.
Waiting for the Rustoleum on the inside of the fender to dry.

MEASURE, MEASURE, MEASURE .......................
Put the fender extensions back on just to make sure.

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cary
post Jan 1 2014, 09:54 PM
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I guess I was overly optimistic.
Too much fiddling and fussing to get the right long tacked in ...............

Couldn't get the front radius of the new long to seat into the inner fender flush and tight. (IMG:style_emoticons/default/mad.gif)
Had to make some modifications. I'll shoot a couple shots tomorrow.
Fiddling & Fussing .........
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cary
post Jan 1 2014, 10:01 PM
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I started with trimming the flange off the firewall. I've decided I'll attach a backing plate to the firewall. It will grab 6" of the upper and 6" of the lower long. Not exactly CW but it will add strength and structure.

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After I trimmed it off .............

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