Cary's 73 1.7 Rustoration Thread Options

[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.

[cary]

It's finally coming back together ................



It's been a long road ...............
But this puts a (IMG:style_emoticons/default/biggrin.gif) on my place.

Door alignment is holding perfect.

[cary]

Finished welding in the left rocker.
Nice .....................

Then moved on to installing the right long inner box.
Pre-drilled the holes.
Sprayed with weld thru primer, again.



Stayed away from the long seam weld. Rosette welds only. No seam welds.
Finished the night with seam sealing over all the welds and the two edges laying on the bottom of the longs.

Today's lesson. Don't spray on TOO much weld thru primer.
Spitter, sputter .............

Today was the last shop day of vacation. Didn't meet my goal of getting the car off the lift. But I'm close.

[saigon71]

Looking good! (IMG:style_emoticons/default/beerchug.gif)

I had to learn the same lesson on weld-thru primer during my restoration. Two light coats and go.

Which weld-thru primer are you using? I had problems with the Eastwood Copper, the can kept clogging.

[cary]

I had been using U-Pol. Which I liked. Their labeling on the spray cans isn't real user friendly. You need to know the product # to what know the product is.

Went to using a can of NAPA zinc enhanced that I'd bought. I'll need to rework my spraying technique. I put it on too thick. Lesson learned ....

[cary]

I'll add a couple notes :

The upper long did end up coming together fine. Had to do a little reshaping on the upper to get it to align with the lower.



Final result ...............