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> Cary going in deep again : MiddleMotors
cary
post Nov 24 2019, 08:16 PM
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Last spring I got a call from a gentlemen that I will call DP. Please come by and look at my car.
My son and I rebuilt the engine in 2012 and never started it.
So Jack and I made a house call. Laying on the floor I saw the hole in the long. (IMG:style_emoticons/default/sad.gif)
Basically I told him car shouldn't be driven unless the rust is repaired.
Let him know where he fell in the line up of projects.

Picked up the car around the first of September.
Original scope of work :
1. Get engine up and running.
2. Get car shifting correctly.
3. Complete PMB brake restoration.
4. End of day, make car reliable

After getting the car on the lift I gave him my best guess on the hours needed to complete the job.
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Drive train on the table
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tygaboy
post Nov 24 2019, 08:29 PM
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Cary, Wow - you weren't kidding about that hole! Be sure DP joins the World and knows what great hands his car is in! (IMG:style_emoticons/default/aktion035.gif)
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cary
post Nov 24 2019, 08:35 PM
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He is, but for the life of me I can't remember it.
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cary
post Nov 24 2019, 08:39 PM
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Next : the lie detectors for the seam sealer removal (IMG:style_emoticons/default/sad.gif)
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cary
post Nov 25 2019, 12:47 AM
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Starting point..
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Here's the engine bay after the lie detector work and jack point removed.
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Andyrew
post Nov 25 2019, 06:56 AM
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Spooling.... Please wait
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Eeeeek that's a nasty one!
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cary
post Nov 25 2019, 09:19 AM
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Time to start cutting my way in. But always thinking, how am I going to weld and encapsulate my way out.
I was hoping the damage was isolated to the jack point area. Not to be.
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Off comes a portion of the floor. No window leakage damage. Just hell hole damage eating its way up.
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Both inner and outer firewalls will need some patching.
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mepstein
post Nov 25 2019, 10:04 AM
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If it was for sale, I'm sure the ad would have read - Light surface rust on one spot, nothing structural.

Thanks for documenting.
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cary
post Nov 25 2019, 07:42 PM
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Thanks, Mark & Chris.
Its all about bringing cars back to life and putting them on the road again.
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cary
post Nov 25 2019, 07:49 PM
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Trimming out the cancer in the engine bay.
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After motor mount removed and treated with OSPHO. Ready for cold galvanizing.
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cary
post Nov 25 2019, 09:54 PM
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Here's a few shots of some other spots that will need some attention.
Hell hole was patched right over the battery acid rusty metal. 30 years ago.
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This is a good shot of the usual battery acid rust damage.
Shows the 2 layers under the hell hole patch.
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Here's shot of the damage to the outside of the upper long / wheelhouse piece.
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cary
post Nov 25 2019, 09:59 PM
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I figured it was about time I check the left rocker to before I submit my sheet metal order.
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Packed with a mud/sand combo, but no rust. (IMG:style_emoticons/default/biggrin.gif)
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cary
post Nov 25 2019, 10:08 PM
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Now it was time to open up the long to see if I could do a partial repair/patch.
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Not to be .................
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cary
post Nov 25 2019, 10:21 PM
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Now its time to get serious. Cutting open the long.
Then it was time to cut the cancer out of the long itself. (IMG:style_emoticons/default/mad.gif)

Using the 2 post lift I need to get the front arm out of the way.
Find my level.
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With screw jack, raise the car enough to move the arm.
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Took a .125" lift to move the arm.
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Then dropped it back to zero.
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cary
post Nov 25 2019, 10:26 PM
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Here's a shot up into the base of the hinge post.
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Lots of sand, lots of rust flakes. I may need to re create the bottom inch of the door
post behind new rocker door post support box.
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cary
post Nov 25 2019, 10:35 PM
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Swung for the fence on the floor pan and hit a home run. Absolutely no degradation on the floor pan under the long.
First a shot of the rusty long up to the edge of the floor pan.
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A close up of what I removed.
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Spot weld cutter drilling out the floor pan.
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cary
post Nov 25 2019, 10:39 PM
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Long trimmed out.
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Here's where we sit till the sheet metal arrives. Backbone won't be cut until I have 3 more screw jacks in my way. (IMG:style_emoticons/default/sad.gif)
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jesse7flying
post Nov 26 2019, 09:22 AM
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Love your threads Cary! Do you have a better shot of how you handle the upper attachment point for the blue reinforcement bars? Thx
Jesse
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Charles Freeborn
post Nov 26 2019, 10:52 AM
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Yowzer. Big project.
Maybe I can see it some time.
BTW, I've got some engine questions for you. Considering building a spare 4 for the race car.
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cary
post Nov 26 2019, 04:12 PM
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QUOTE(jesse7flying @ Nov 26 2019, 07:22 AM) *

Love your threads Cary! Do you have a better shot of how you handle the upper attachment point for the blue reinforcement bars? Thx
Jesse


I'll shoot a couple shots tomorrow.
Someone on Instagram wants to buy a set.
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