Cary's 73 1.7 Rustoration Thread Options

[cary]

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 ................

[cary]

Here's yesterday's repair. Making those little patches is a lot of fiddling..............

[cary]

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.

[cary]

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 .........

[cary]

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.



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

[cary]

After I finished modifing the front end of the long.
I made the MONEY CUT .................
Only measured about 6 times.



Bad news. It will need more fiddling. The upper long is wider than the lower long. (IMG:style_emoticons/default/mad.gif)
And the bottom radius of the upper long doesn't match the back lower radius of the lower long.
It will need more fiddling

[cary]

Ended the day with measuring the door vs. the long on the inside.

Drivers side, long already attached.



I'm real happy with that ...................... (IMG:style_emoticons/default/smilie_pokal.gif)

The right side ............... not so much. Glad its not attached ......................



A little more fussing with that front end will lower the front a 1/4 inch.

[sixnotfour]

that seals the deal for me , I am going to salvage a right inner long for my project...Great Job Cary

[cary]

Here's where I struggled today.

This is how the front end of the RD piece comes.



I finally found the picture I was looking for.
Here's how it came from the factory.



Here's what needs to happen ..................



THEN it will slip into the inner fender like it should.
Waste of a 1/2 day. No wonder restorations cost $200k.

[cary]

that seals the deal for me , I am going to salvage a right inner long for my project...Great Job Cary

If the front inner fender is in good shape. That's what I'll do next time too.
What we need is just the bottom with the inner rocker flange and about a 1 1/2" upright flange. That would take care of most rust damage repairs.

[maddin]

...what an incredible display of craftsmanship! :-)

[cary]

Here's the trimming I needed on the front end of the long.



Upper Trimmed
I needed to modify the curve to match the inner fender radius



Lower Trimmed



The Sharpie mark is where I finally cut off the lip too.

[cary]

Double Post (IMG:style_emoticons/default/headbang.gif)

[cary]

Finally, the right long installed ............ (IMG:style_emoticons/default/smilie_pokal.gif) (IMG:style_emoticons/default/smilie_pokal.gif) (IMG:style_emoticons/default/smilie_pokal.gif)



Tough welding, under the car. Arm stuck up throw a hole. Helmet all jammed up and twisted. Over did the weld ............... (IMG:style_emoticons/default/mad.gif) (IMG:style_emoticons/default/mad.gif)



Happy with the penetration though .............

I'll wait to tidy up the welding till after I remove the floor. (IMG:style_emoticons/default/welder.gif)
Plus I'd like one more behind the heater tube.

[cary]

Here's the long seam weld. Should have been better looking.
Tried to pass thru the tacks. I should have knocked them down with the grinder before I finished the seam welding.

[cary]

Might want to build one of these clamps to squeeze the long into the right size.
Mine came a bit splayed open.

[cary]

Another Double Post .......... (IMG:style_emoticons/default/hissyfit.gif)

[cary]

Ended the night with Super In Law building inner box.





We'll cut and add the upper and lower flanges in the am.
Needs a little trimming in that picture ...........

[cary]

Finished up the inner box fab.







It will be attached with predrilled holes and rosette welded.

[cary]

I'm thinking I might not use the stiffeners.



Coat them with WD 40 and shrink wrap them up.