metal fabbers...report., I need your help Options

[Trekkor]

I'm repairing the battery tray and related hot spot. (IMG:http://www.914world.com/bbs2/html/emoticons/unsure.gif)

I need your tech advice on the procedure.

I want to first make paper templates and then fit the sheet metal. Maybe hang it with rivets or screws before the big weld off.

Stock look is not important to me. Just needs to drain and support the new battery tray and pedestal.

I will sand off the remaining surface rust before applying rust converting primer. I'm scratching the naval jelly approach.

Also, please post pics of your repaired areas.

Here's my project.

Thanks, as usual! (IMG:http://www.914world.com/bbs2/html/emoticons/clap.gif)

KT

[airsix]

In the picture below I've marked off the pieces I'd cut and numbered them in the order I'd weld them in. The first piece would be the firewall patch. I'd clean out all the seam sealer goop and weld this in from inside the passenger compartment. Then touch it up if needed from the engine side. Next would be the vertical portion of the longitudinal because if you save it for later you won't be able to get to it. Also, it provides something to weld too when you get to the horizontal top patch. Since the tongitudinal top is curved you'll need to do some 'beat to fit' as they say. Rough out your patches with plenty of overlap. I put a question mark on the longitudinal top patch because I'm undecided whether I'd make it short, or longer (into the area with the question mark). It depends on how weakened that area looks to you. Since I've shown a top patch with so much overlap I'd probably drill holes above the overlap areas for some rosette welds to tie it together really strongly. This is just my suggestion and I do not have an advanced degree in rustoration science.

-Ben M.