BUILD-OFF CHALLENGE: Eisberg rustoration, Need some input... Options

[mbseto]

Funny, I am as nervous starting this thread as I was to start cutting into my car.

I resolved to start a rustoration thread when I made my first cuts, so here it is. I'm hoping the community will pipe in periodically with any, "Don't do that!", "Do it this other way!", "Do this first!", or "Don't forget this!" comments that are appropriate. Any and all guidance will be appreciated.

So here's the car as I got it, not quite a year ago:


Started out doing a little engine work to get it running, then drove it around a little bit before starting to take it apart. Took the engine out, put it up on a dolly, took out much of the interior and suspension, and this is how it sits now:






After cleaning out the inside and seeing the rust, it was hard to believe we were driving it at all. These are the first cuts, just straightening out the edges of the rust holes really.


More pics coming soon, I'll be documenting the extent of the damage and forming a battle plan.

[mbseto]

Took out a little of the door frame to get those rosettes in there. Wasn't really sure until this point whether I could get the long replaced without cutting the fender. Glad I took Rick's advice.


Need to replace the bottom of the door post. The PO just slapped a plate on there. I looked through several threads for this, everyone has a different name for it: door post, torque box, hinge post base... Whatever it is, cut a pattern:


Here's another little piece that was cut away to access the rosettes at the front of the long:


Bent the hinge post base to shape and trimmed to fit:


Blew some holes trying to mate the original metal to the new metal. Didn't really want to post this pic but sometimes your purpose is to serve as a warning to others I guess.


Pondered over that for a bit and decided that putting in a single piece with a little overhead welding is better than two tiny patches.




And finally the sill is tacked in place. This gets me up to today and I was surprised at how good it felt just to get the sill back on. You may notice the door braces are gone from this side. After getting the long completely welded in place, but before starting on the door port and sill, I took them up and brought the door up from the basement and held it in place. It looked about like I had hoped, no gross errors anyway. I know the car will settle once it is back on its feet, hopefully the gaps stay good.