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Old 02-01-2014, 09:47 PM   #51
Sir Psycho
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What media blaster are you using?
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Old 02-02-2014, 08:38 AM   #52
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What media blaster are you using?
Using a cheapo Harbor Freight deal. It works pretty well. It's the one with the grey plastic bucket for the media (holds about 50 lbs). You can see the bucket portion of it in a couple of the photos.
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Old 02-08-2014, 09:41 PM   #53
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Rear suspension is off to High Performance Auto Service for poly bushings. Did some more spot blasting and sealing in the rear end yesterday.

Uncovered a small patch of rot behind the driver's side rear wheel:

[IMG][/IMG]

Also blasted around the rot in the inner wheel well on the driver's side rear:

[IMG][/IMG]

[IMG][/IMG]

Today I figured it was time to have another go at welding.

The welder that my brother has been nice enough to loan me for the duration of the project:

[IMG][/IMG]

You can see the setting that I'm using dialed on there. It's what the info sheet on the welder recommended for 20 gauge.

[IMG][/IMG]

I tried to find some shielding gas and solid core wire today but all the places that sell them were closed. Here's the wire I'm using:

[IMG][/IMG]

First cut up some pieces and practiced on them:

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

Some of the welds were pretty decent, others not so much, and every so often I was blowing through the metal.

Here's what the back side looked like:

[IMG][/IMG]

I did another practice butt weld and felt a little better about the result. I was going to keep cutting stuff up and welding it back together but figured I might as well combine practice with some practical work where the results wouldn't show if they weren't good. This is that inner wheel well rot on the driver's side rear wheel. There's a lap joint that is spot welded and it looks like the panel fitting wasn't really great and water got in and ate away where the to panels overlapped.

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

I was happy to find that the area between the rear quarter inner/outer is nice and solid. I'll spray it with Eastwood frame sealer before I close it up.

[IMG][/IMG]

I cut a patch out of a 240 floor pan repair section scrap that I had left over from Project Senf.

[IMG][/IMG]

Again, a few decent welds, many mediocre welds, and a few blow throughs....but serviceable

[IMG][/IMG]

You'll have to take my word for it that the photo makes the end result look a lot worse than it is. For some reason the ground area shows up as dark black....though it just looks like ground metal to the naked eye.

[IMG][/IMG]

Next I need to weld in a patch for that overlaps behind this piece and then move on to the rot on the back side of the quarter panel. Hoping that if I keep at it my technique will improve eventually.
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Old 02-08-2014, 10:04 PM   #54
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You should try running it hotter and with more wire. Also, get shielding gas.

You aren't doing yourself any favors by using flux core for sheet metal work. The main problem is that you really need to clean the weld area after every start/stop. If you don't, you end up shooting dingleberries all over the place because the arc won't start properly. And you will tend to get a lot of slag inclusion as well.
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Old 02-08-2014, 10:21 PM   #55
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Karl - thanks for the suggestions. I will give hotter/faster a try. Yes on the gas; ran around today trying to find a welding supply house that was open but had no luck. Will be picking up a bottle this week. I'm glad you explained the bit about the flux impact on arc; did not know that...but I definitely experienced that problem.
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Old 02-09-2014, 02:08 AM   #56
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Hey, much improved!
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Old 02-13-2014, 08:40 PM   #57
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All hail shielding gas....well, I hail it no matter whether anyone else does

[IMG][/IMG]

This is the inside of the driver's side rear wheel well/inner fender. One patch is mostly stitched in, two pieces below it have been ground down (more or less).

I can't believe how much neater and cleaner it is working with the gas. I still have to figure out how to avoid getting such "proud" welding beads, but I can see both sides of this patch and I'm getting what looks like good penetration. Plan to practice more tomorrow and Saturday....
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Old 02-14-2014, 10:24 PM   #58
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Finished the patch on the driver's rear wheel well/inner fender.

[IMG][/IMG]

Started patching up the inside of the rear valence:

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

Still need to finish stitching in the last bits and then finish grinding it. Hope to get the remaining patches done on the rear valence tomorrow...
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Old 02-28-2014, 08:49 PM   #59
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Had the day off and spent it prepping and welding.

Here's the passenger side wheel well leading to the inner rockers. It's cleaned up and ready to be patched....if not for the other stuff that I found:

[IMG][/IMG]

This is the same wheel well but the outer at about the 1 O'clock position. Two small rust through spots that didn't seem too bad:

[IMG][/IMG]

[IMG][/IMG]

Started investigating to see how far the rot went. Here's the bottom of the inner quarter. You can see that it's perforated a good 5-6" up, at least. You can also see that where the outer and inner rockers meet to form the wheel well is all messed up. The car was apparently dinged right under the rubber trim piece in the front of the rear wheel well. Only 2 of the spot welds from the ~1 O'clock position to the bottom of the wheel well were still intact.

[IMG][/IMG]

Here's another look at the inner wheel arch where the spot welds are all failed. I pried the pieces apart to get all the loose scale and crap out of there and figure out how much of it needs replacing. Kind of a mess.

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

Basically figured at this point that I am going to need to find a patch panel for the outer and inner quarters here. This is just a driver restoration but I don't want to sink money into paint only to have the paint fail due to hidden rot and stuff. Now looking for the patch panels.

In the meantime I figured I'd deal with the small inner/outer rot on the back side of the same wheel well:

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

Figured I'd do the outer patch on the rear quarter on the driver's side while I was at it. Here's the before:

[IMG][/IMG]

Here's the after:

[IMG][/IMG]

[IMG][/IMG]
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Old 03-01-2014, 07:53 PM   #60
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Started to clean out the rotted cross members and rockers on the driver's side this afternoon. There are so many body panels that meet in the rocker area that I'm confused about where to start.

My floor pan has some rot where it meets the rocker, the inner rocker is rotted out in a couple of spots, and there is some rot through on the outer rocker towards the front.

I'd appreciate any advice on how to tackle a rocker repair.

Should I start by removing the outer rocker skin? What's the best way to do this? I see all the spot welds that run along the bottom of the rocker and also where it joins up with the door sill. Should I just drill out the spots? How is the rocker joined with the front fender and rear quarter? Are there spot welds between the fender sections and the flange of the rocker that tucks underneath them?
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Old 03-02-2014, 07:48 PM   #61
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Never mind....

Looked at it with a fresh set of eyes this afternoon and figured it out:

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

The inner rocker looks simple enough to patch up but the mid rocker is a twisty mess and appears to also serve the purpose of providing a vertical flange on the bottom for the bottom of the inner rocker to be welded to. Wolf Steel in Quebec sells rocker kits and I've got a request out to them to see if they'll sell just the mids so that I can use them to patch fore and aft.

Here's the section of floor pan that I removed. It's only a rotted a little bit towards the inner rocker; plan on patching it up and re-using it.

[IMG][/IMG]
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Old 03-02-2014, 09:12 PM   #62
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Your flicker photos went private.
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Old 03-02-2014, 09:25 PM   #63
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Quote:
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Your flicker photos went private.
fixed; thanks for the heads up
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Old 03-03-2014, 08:44 PM   #64
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Plinking away at cleaning up the rockers. Would have gotten more done but I think my $9.99 HF high speed cutter gave up the ghost....got good service out of it while it was working though. The middle sill/rocker is ~ 20 gauge so I think I'll be able to do all the forming that I need to without any trouble.

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

Finished cutting out the weakened sections of floor board as well.

[IMG][/IMG]
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Old 03-15-2014, 10:42 PM   #65
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Been plugging away on the driver's side rocker. These are from a couple weeks ago, still in the process of cleaning out the rot on the mid sill and figuring out how to work the repair.

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

Got a HF blast cabinet and tested it out on the rear brake backing plates, then shot them with wheel paint.

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

This is the outer rocker. The hole on the left of the photo is just aft of the bottom of the front fender section.

[IMG][/IMG]

Filling in the pilot holes from drilling out the spot welds and patching up some thin spots on the bottom of the outer rocker:

[IMG][/IMG]

[IMG][/IMG]

There is a solid section of the outer rocker panel more or less under the door pillar. This patch is to repair the hole just aft of the front fender section and to tie into the solid section.

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

This is how it looks from the outside. I'm going to have to work to neaten up/even up the seam between the outer rocker and the front fender.

[IMG][/IMG]

Plan to finish stitching this patch in after work over the course of this week.
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Old 03-23-2014, 08:00 PM   #66
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Still working on driver's side rocker. Got the outer patch finished.

I got the Eastwood spot weld kit and used it here for the first time. Works well; squeeze the trigger and count to four-one-thousand and that's it. This is the flange from the outer rocker extension where it ties into the bottom of the outer rocker.


[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]


I need to get a metal brake before I tackle the mid sill so I moved on to cleaning up the front longitudinal support (from frame rail to inner rocker under the driver's feet). Of course there was more rot than I expected:

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

[IMG][/IMG]

Overdid it a bit on the primer...those are droplets of wet primer there:

[IMG][/IMG]

Next step is to patch up the frame rail where it kicks up toward the engine bay. There are a few perforations and one small section cut out already but it doesn't appear too bad (hit it in multiple spots with the MIG welder looking for blow through and only found a couple of weak spots. The hole near the tow hook seems to be related to the factory welding there.

[IMG][/IMG]

Last edited by didenpx; 03-23-2014 at 08:16 PM..
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Old 03-24-2014, 12:27 PM   #67
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You are battling some serious rust. Reminds me of the P1800S I restored. It was worth it! Every time I stopped for gas someone would come over and ask me about the car. Looking forward to seeing how this plays out for you.

Have you considered Silicone Bronze wire for you non structural welds? I find you get far fewer blow through on thinner sheet metal plus it handles less then perfect surfaces better then traditional carbon steel.
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Old 03-24-2014, 07:32 PM   #68
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I'll look into the silicone bronze wire; thanks for the tip.

There's definitely more welding to be done than I counted on, but I think once I get the driver's rocker and the frame rails sorted out the rest of it will go faster. Definitely re-assessing my original goal of getting it on the road before the snow flies this fall.

Do you still have your 1800S?
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Old 03-24-2014, 07:49 PM   #69
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I wish I still had it. Unfortunately I lost interest in the car many years ago and it wasted away. Its pretty sad I guess. I ended up selling it to a guy who claimed he was going to resurrect it. I started work on it in 1997 and I was driving it by 98. After finishing the body I performed some major engine upgrades to it. Electronic ignition from Mallory, Isky cam, and Weber DCOE's. I never had it dyno'd but it was rocket.
Like I said I couldn't stop for a tank of gas without someone asking me about it. To this day I still think it is one of the most pleasing body designs to look at.

Here's a photo of it in 2002.
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Old 03-25-2014, 07:14 AM   #70
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Beautiful car!
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Old 03-29-2014, 07:45 PM   #71
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Made a lot of progress on the driver's side rocker mess.

Got the forward portion of the inner sill patched up:

[IMG]Driver's Forward Section Inner Rocker - Spot Welds[/IMG]

[IMG]Outside View of Lower Forward Inner Rocker Spot Welds[/IMG]

[IMG]Forward Section of Driver's Inner Rocker #2[/IMG]

[IMG]Forward Section of Driver's Inner Sill[/IMG]

Patched up the frame rail section at the kickup and towing hook:

[IMG]Driver's Side Frame Rail Kickup Patch[/IMG]

[IMG]Driver's Frame Rail Patch Behind Tow Hook Complete[/IMG]

Got the mid sill all patched up:

[IMG]Mid Sill Patch Fitted[/IMG]

[IMG]Mid Sill Patch[/IMG]

[IMG]Mid Sill Patch[/IMG]

[IMG]Mid Sill Patch[/IMG]

[IMG]Mid Sill Patch[/IMG]

[IMG]Mid Sill Patches #2[/IMG]

[IMG]Ready for Inner Rocker Welding[/IMG]

Inner rocker patch fitted and ready to weld in:

[IMG]Inner Rocker Patch[/IMG]
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Old 05-10-2014, 09:49 PM   #72
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Still plugging away, but any hope that this will be on the road by August has been vanquished.

Got the driver's side floor pan patched up:

[IMG]Floor Pan Before Tacking[/IMG]

[IMG]Floor Pan Tacked In[/IMG]

[IMG]Floor Pan Tacked-In (Overview)[/IMG]

[IMG]Floor Pan - Transition to Rear "Seat" Tacked In[/IMG]

[IMG]Front Floor Pan Patch[/IMG]

[IMG]Front Floor Pan Patch #2[/IMG]

Got the front cross member (under feet) and frame rail extension patch (under butt) welded in:

[IMG]Floor Pan Front Patch - Ground[/IMG]

[IMG]Front Cross Member Tacked In[/IMG]

[IMG]Front Cross Member Tacked in #3[/IMG]

[IMG]Front Cross Member Tacked In #4[/IMG]

[IMG]Prepping for Rear Cross Member[/IMG]

[IMG]Rear Frame Rail Primed[/IMG]

[IMG]Front and Rear Cross Members Welded & Primed[/IMG]

[IMG]Firewall and Cross Members With SEM Undercoating[/IMG]

[IMG]The Ugly & The Good[/IMG]

I didn't match the original contour of the floor pan when I patched things up and as a result I had to cut the pan just forward of the rear frame rail extension (the frame rail is taller towards the front of the car, shorter to the rear). Once I had the cross member fully welded in I had to fill this in.

[IMG]Plug Welds for Rear Cross Member Ground[/IMG]

[IMG]Closing up Floor Pan[/IMG]

[IMG]Floor Pan Painted - With Rear Section Sorted[/IMG]

Next task: patch up the small section of rot under the parking brake lever:

[IMG]Patching Under Parking Brake #1[/IMG]

[IMG]Patching Under Parking Brake #3[/IMG]

[IMG]Patching Under Parking Brake #5[/IMG]

Next task: sort out the sills and quarter panel between the driver's door and rear wheel well:

[IMG]Untitled[/IMG]
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Old 06-01-2014, 08:52 PM   #73
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Patching rear section of left inner sill

[IMG]Left Rear Inner Sill Patching #5[/IMG]

[IMG]Left Rear Inner Sill Patching #3[/IMG]

[IMG]Left Rear Inner Sill Patching #2/IMG]

[IMG]Left Rear Mid Sill Repair Piece[/IMG]

[IMG]Left Rear Sill & Rocker Repair #4[/IMG]

[IMG]Left Rear Sill & Rocker Repair #3[/IMG]

[IMG]Left Rear Sill & Rocker Repair #2[/IMG]

Got the repair section for the right rear wheel arch. Awesome piece (thanks High Performance!). This will probably wait til later in the month or July....

[IMG]Passenger Rear Wheel Arch Repair Piece #2[/IMG]

On to the radiator core support....finally.

Filling in the holes left from drilling out the old spot welds:

[IMG]Filling in Plenum[/IMG]

Got distracted and bored and figured I might as well pull out the ding in the front cowl. I drilled a boatload of holes, used a slide hammer, and then welded them closed. This after attempts to work it from behind were unsuccessful (not enough room to work the hammer)

[IMG]Cowl Ding Pulled Out[/IMG]

[IMG]Cowl Ding Pulled Out #2[/IMG]

Test fitting the core support:

[IMG]Test Fitting Radiator Core Support #4[/IMG]

Holes drilled for the plug welds

[IMG]Radiator Core Support Ready for Installation[/IMG]

Ready to start the plenum to core support plug welds:

[IMG]Radiator Core Support Ready for Welding #3
Welding (finally!):

[IMG]Project Roedluvan 1561[/IMG]

Plug welds to plenum done:

[IMG]Radiator Core Support Top Spot Welds Complete[/IMG]

Still need to complete welding to the frame rail extensions.....next weekend

Last edited by didenpx; 06-01-2014 at 09:10 PM..
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Old 06-15-2014, 07:44 PM   #74
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What size holes are you plugging on the core supp't..When welding two panels together I'd suggest filling a 5/16 hole.If welding three pieces together I'd use a 3/8 hole.If you use too small of a hole it's difficult to start the weld in the back piece to fill outwards,plus you won't have enough strength if the hole is to small.
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Old 06-15-2014, 07:56 PM   #75
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This looks sooooo familiar. Amazing how much rust a nice looking car can hide from you.
Looking at the last pic, I think you need more power and less wire, but you're learning fast! Nothing like jumping in and gettin' bizzay!!
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