62 OlllO
Well Oiled
Until my back starts feeling better, I'm limited to putt-sing and sy-phoring...and the money is of short supply around this house...so I have to make panels apposed to buying repo's @ $65.00 each. The passenger side is the worse, so my first attempt is where I started today. I took my portable saw-sall and cut the bottom of the cowl where the rust had taken up residence. If you noticed, I cut the metal that is behind the chrome trim, which will hide the weld seam and my body work. NOTE: some of this panel has an inner metal part that you don't see, plus spot welds. I decided to cut it all out after unsuccessfully trying to break the spot welds.
[attachment=2:396lwek1]Rust 012.jpg[/attachment:396lwek1]
The piece I cut out made a perfect copy for what needed to be replaced with new metal...breaking the seam edge (radius) wasn't hard, most of it was rust. Laying it flat on new metal made it a fast task making the new piece. Cutting the radius with hand tin shears and going to the break for a 90 degree bend...then it was just the matter of solid welding the edge-seam together (radius), grinding and checking how it will fit. To help the welding process and strength the edge seam I place a metal rod and welded it to the edge. The hole in this piece is for the front fender, I will drill an over-size hole and weld a new nut for the new bolt. To get at this nut, you would have to cut a hole on the inside metal brace....I like it so far.
[attachment=1:396lwek1]Rust 014.jpg[/attachment:396lwek1]
I know, I'm not finished yet, I have to make the inner metal brace ( replacing rust ) and tack weld the new metal in, but I figure I just saved myself $65.00 + freight
[attachment=0:396lwek1]Rust 013.jpg[/attachment:396lwek1]
Hopefully this will inspire you in your own project. I don't want to imply however that I'm doing this has a professional, I'm a tinker! I'm just trying to save a buck, remove the rust with new metal and minimize the bondo. After it is all together I will treat the inside new metal ( you can't see ) for rust and paint.
I will keep you posted on further progress later...
[attachment=2:396lwek1]Rust 012.jpg[/attachment:396lwek1]
The piece I cut out made a perfect copy for what needed to be replaced with new metal...breaking the seam edge (radius) wasn't hard, most of it was rust. Laying it flat on new metal made it a fast task making the new piece. Cutting the radius with hand tin shears and going to the break for a 90 degree bend...then it was just the matter of solid welding the edge-seam together (radius), grinding and checking how it will fit. To help the welding process and strength the edge seam I place a metal rod and welded it to the edge. The hole in this piece is for the front fender, I will drill an over-size hole and weld a new nut for the new bolt. To get at this nut, you would have to cut a hole on the inside metal brace....I like it so far.
[attachment=1:396lwek1]Rust 014.jpg[/attachment:396lwek1]
I know, I'm not finished yet, I have to make the inner metal brace ( replacing rust ) and tack weld the new metal in, but I figure I just saved myself $65.00 + freight
[attachment=0:396lwek1]Rust 013.jpg[/attachment:396lwek1]
Hopefully this will inspire you in your own project. I don't want to imply however that I'm doing this has a professional, I'm a tinker! I'm just trying to save a buck, remove the rust with new metal and minimize the bondo. After it is all together I will treat the inside new metal ( you can't see ) for rust and paint.
I will keep you posted on further progress later...