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> Rebuiding Inside-out
bkrantz
post Feb 23 2020, 08:27 PM
Post #281


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Before welding the inner patch in place, I wanted to take advantage of the hole to access the inside of the outer fender panel. This had a PO repair with LOTS of bondo.


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bkrantz
post Feb 23 2020, 08:28 PM
Post #282


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The fill was at least 1/8 across the entire panel.


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bkrantz
post Feb 23 2020, 08:30 PM
Post #283


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To minimize the mess I mounted the Fein dust shield on the angle grinder. Not 100% but much better than without it.


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bkrantz
post Feb 23 2020, 08:31 PM
Post #284


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Got the panel cleaned up, and did some initial smoothing. More work to come.


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bkrantz
post Feb 23 2020, 08:35 PM
Post #285


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I also started on the top of the sill. This normally has two layers of sheet metal, but I decided to add a third inner layer patch. This extends about 2 inches forward and rear of the hole.


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bkrantz
post Feb 23 2020, 08:36 PM
Post #286


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Here it is welded in place. I will need to grind this down to fit the "middle" panel patch.


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bkrantz
post Feb 23 2020, 08:37 PM
Post #287


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And at the same time I tack welded the inner fender wall patch, and got the edges aligned.


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bkrantz
post Feb 24 2020, 09:42 PM
Post #288


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Did some grinding and then tried to finish the butt seam welding around the patch. Got it done, but very frustrating with lots of burn-throughs. The final result is ugly, with lots of thick spot welds and big boogers. That will lead to more quality time with my grinder.


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bkrantz
post Feb 26 2020, 09:29 PM
Post #289


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After a couple of hours of quality time with my angle grinder and die grinder, things are looking better. A few spots and holes to re-weld.


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bkrantz
post Feb 26 2020, 09:31 PM
Post #290


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Getting ready for the next patch, the outer layer on the top of the sill.


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bkrantz
post Feb 27 2020, 09:03 PM
Post #291


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I feel like I am in a groundhog day loop with the inner fender wall patch. After grinding yesterday, I checked the weld with a light inside the fender. This revealed a Buch of pin holes and thin spots, and a few segments where the weld did not penetrate.

So weld (#2) all suspect areas.


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bkrantz
post Feb 27 2020, 09:04 PM
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And grind (#2).


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bkrantz
post Feb 27 2020, 09:05 PM
Post #293


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Check with the light inside again, more holes!

Weld (#3).


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bkrantz
post Feb 27 2020, 09:06 PM
Post #294


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Tomorrow, if I hear Sonny and Cher on the garage radio, I may go back to bed.
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bbrock
post Feb 27 2020, 09:19 PM
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QUOTE(bkrantz @ Feb 27 2020, 08:06 PM) *

Tomorrow, if I hear Sonny and Cher on the garage radio, I may go back to bed.

Boy do I know that pinhole routine. Thank goodness I never woke up to I've Got You Babe. (IMG:style_emoticons/default/av-943.gif)
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bkrantz
post Feb 28 2020, 09:25 PM
Post #296


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Well, I was hearing "I got you babe" again today for sure.

After grinding (3rd time) I had more holes and bad weld bits, especially in one spot.

So I finally did the right thing (I hope) and cut out the worst section. The size and shape shows where I was chasing a growing hole, especially into the original sheet metal.


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bkrantz
post Feb 28 2020, 09:28 PM
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I formed a new mini-patch and welded it in place--much better.


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bkrantz
post Feb 28 2020, 09:30 PM
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At the same time, I welded a few more holes around the original patch (4th time), and then ground them down (4th time). A quick look showed only a couple of pin hole around the new mini-patch. I might be able to beat the groundhog!


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bkrantz
post Feb 28 2020, 09:32 PM
Post #299


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BTW, here in the back(!) side of the small area I cut out. Pretty nasty (and not the work quality I am aiming for).


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bkrantz
post Feb 29 2020, 10:12 PM
Post #300


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I beat the groundhog!

I did hear a faint echo of Sonny and Cher, but after welding and grinding just 3 or 4 spots, the inner fender wall patch is done. Not pretty, but should finish fine after some cosmetic work later on.



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