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> Rebuiding Inside-out
bkrantz
post Feb 29 2020, 10:13 PM
Post #301


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Now time to move on. Here is the middle layer patch for the top of the sill, final fit.


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bkrantz
post Feb 29 2020, 10:15 PM
Post #302


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And welded in place.


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bkrantz
post Feb 29 2020, 10:16 PM
Post #303


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And here is the top layer patch, nearly fitted.


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bkrantz
post Mar 1 2020, 09:36 PM
Post #304


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Started welding on the last layer, beginning with the flange against the inner fender wall. Nice to have the car on the rotisserie, so I could weld with the flange and fender wall horizontal.


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bkrantz
post Mar 1 2020, 09:40 PM
Post #305


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I ground down the welds along the flange and they looked good, so went on the weld the main part of the patch. Mostly straight-forward, except along the seam against the remaining original pitted metal. That led to some more ugly welds.


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bkrantz
post Mar 1 2020, 09:42 PM
Post #306


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I still have to grind this down and check the weld success, but I am happy to be close to done on closing up the hell hole, only 6 months after I cut a hole in the top to explore for internal rust.


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tygaboy
post Mar 1 2020, 10:56 PM
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A bit of (IMG:style_emoticons/default/sawzall-smiley.gif) (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif)

And now some (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/aktion035.gif) (IMG:style_emoticons/default/smilie_pokal.gif)

Super job! Isn't it a great feeling when it's "job done"? Keep up the great work and detailed documentation.
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bkrantz
post Mar 2 2020, 09:55 PM
Post #308


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Thanks. Milestones are good for my mental health, as are my documentations and posts.

Anyway, here is the finished (for now) product. A bit lumpy, but it should be functional and look OK, especially after prep and paint.


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bkrantz
post Mar 2 2020, 09:56 PM
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On to the firewall. Here's a cardboard template fit for the lower patch.


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bkrantz
post Mar 4 2020, 08:44 PM
Post #310


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Small patch cut and formed, with holes in the flanges for plug welds.


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bkrantz
post Mar 4 2020, 08:45 PM
Post #311


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Final fit.


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bkrantz
post Mar 4 2020, 08:46 PM
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After welding and grinding. Now time for the bigger hole...


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bkrantz
post Mar 4 2020, 08:47 PM
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And from the engine side.


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bkrantz
post Mar 5 2020, 10:02 PM
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Spent about an hour today working on forming the upper firewall patch, including the diagonal raised ribs. Still needs more work in the complex corner on the right side.


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FourBlades
post Mar 6 2020, 08:13 AM
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Looking good!

You are making good progress.

John
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9146C
post Mar 6 2020, 09:20 AM
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Very impressed with your fabrication work!
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tygaboy
post Mar 6 2020, 09:26 AM
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Fabricationlous! (IMG:style_emoticons/default/smash.gif) Nice looking patch piece. You're making great progress. (IMG:style_emoticons/default/smilie_pokal.gif)
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bkrantz
post Mar 6 2020, 06:03 PM
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Thank, guys. Just a bit of time to play body shop today. The corner fold looks better, and I am ready to trim this patch.


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bkrantz
post Mar 7 2020, 09:44 PM
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Spent a couple of hours fitting the new patch. After the initial cut, I had it in and out about a dozen times--definitely trying to attain the Zen level of patience. Here it is near the end of fitting trials.


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bkrantz
post Mar 7 2020, 09:45 PM
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And after tack-welding. Time for more patience.


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