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> Rebuiding Inside-out
bkrantz
post May 12 2020, 07:56 PM
Post #661


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Fist dent came out nicely.


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bkrantz
post May 12 2020, 07:57 PM
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Second dent was going well, and then I pulled too hard!


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bkrantz
post May 13 2020, 08:28 PM
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Got the trunk lid done today. I welded up the hole I tore yesterday, and the old hole from a PO puller repair.


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bkrantz
post May 13 2020, 08:30 PM
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I used the same technique to pull the remaining significant dents in the trunk ribs.


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bkrantz
post May 13 2020, 08:33 PM
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While I had the welder going, I reattached the trunk latch mount inside the rear panel.


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bkrantz
post May 13 2020, 08:38 PM
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Getting close to clearing the list!


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bkrantz
post May 14 2020, 08:41 PM
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On to the next/last bit of significant metal work on the body shell: battery tray and support. Here are the new pieces.


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bkrantz
post May 14 2020, 08:43 PM
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I am still pondering how I want to do this (fully welded, weld in the support and bolt in the tray, other?).


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jaredmcginness
post May 15 2020, 10:05 AM
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Hmmm. I need to finish my battery tray and engine shelf this week. Was hoping to find some answers to your question too.

I think I am going to fully weld everything. Spot welds around the base.
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bkrantz
post May 15 2020, 09:15 PM
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I am leaning that way, too. I know I will install a sealed battery, and so the risk of acid spill is mush less than the risk of mount failure.
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ElCee
post May 16 2020, 04:14 AM
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QUOTE(bkrantz @ May 15 2020, 04:43 AM) *

I am still pondering how I want to do this (fully welded, weld in the support and bolt in the tray, other?).


Here are some photos showing how I fitted my battery box.

1) First I welded 3 nuts on some strips and welded those strips to the underside of the battery box. You can then precisely drill the 3 mounting holes in the separate console.
2) The new console can then easily be welded where the old console was. That way you can also weld the inside of the console properly. For the integrity I also made a support to the inner screen.
3) Check whether the battery box can be properly secured with 3 bolts and disassemble the battery box again. Once disassembled both the console and the battery box can be well protected from rust.
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bkrantz
post May 16 2020, 08:54 PM
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Thanks--very clever solution. I decided to go old school...
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bkrantz
post May 16 2020, 08:58 PM
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And weld everything in place.

But first I pulled out the battery tray that was on the car. It had plenty of undercoating and other gunk, but the quality of the pressing, the presence of cable tabs, and the red primer makes me think this is a factory replacement part.


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bkrantz
post May 16 2020, 09:00 PM
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The underside is clean, and never welded.


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bkrantz
post May 16 2020, 09:01 PM
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I used some solvent (3M Adhesive Remover seems to work best) to strip off the undercoating.


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bkrantz
post May 16 2020, 09:02 PM
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In fact, this piece was only attached by some epoxy along the edge against the inner fender wall.


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bkrantz
post May 16 2020, 09:06 PM
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I started with the support, with some plug welds into the side of the longitudinal.


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bkrantz
post May 16 2020, 09:07 PM
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And then more plug welds on the side flanges.


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bkrantz
post May 16 2020, 09:08 PM
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Here is the tray clamped in place.


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bkrantz
post May 16 2020, 09:09 PM
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I started with more plug welds from inside the fender through the inner wall into the edge of the tray.


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