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> One more out of the ashes., New Year new project.
heavydriver
post Jan 15 2009, 01:15 PM
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Here are the somewhat cleaned up edges of the tunnel. I am thinking that they can be reflanged and a new floorpan installed. I am open to ideas from those who have btdt.
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heavydriver
post Jan 15 2009, 01:16 PM
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heavydriver
post Jan 15 2009, 01:17 PM
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heavydriver
post Jan 15 2009, 01:17 PM
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heavydriver
post Jan 15 2009, 01:18 PM
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Other side.
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heavydriver
post Jan 15 2009, 01:19 PM
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heavydriver
post Jan 15 2009, 01:20 PM
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VaccaRabite
post Jan 15 2009, 01:21 PM
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I know this first hand. Cutting while mad at your car for being way more rusty then it should have been leaves you with much larger repair jobs then need be. When it is all said and done, the tunnel will be covered in carpet, and no one - not even the snootiest CW judge - is going to take apart your interior to make sure that your tunnel is factory looking.

The good news is that anyhting you cut away can be welded back into place later. its just that welding can take a while to do right, so the more welding you have to do, the more time you spend on or under the car rather then in it driving about.

If you need to make a new flange for the tunnel, do that and tack it in place before you remove the floor (don't weld it to the floor, obviously). This way you are not left playing the guessing game about where the flange needs to be so that you are not deflecting the floor when it gets welded in.

I have owned my car for 3 years and change and have never driven it, mainly cause I see something and jump in with both feet before looking for the more efficient route, or just fix something that was not really broken to begin with.
Zach
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heavydriver
post Jan 15 2009, 01:23 PM
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The only good sections are the forward and aft sections of the tunnel. The crossmember is just like the tunnel so pics would be redundant.

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heavydriver
post Jan 15 2009, 01:25 PM
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I would have cleaned up the floors a little better but I stopped when I decided to change them. Right now the sheetmetal wanted list includes the floors and the inner and outer firewalls. ugh.

Would any of the central Fl. guys have a pair of door braces they can loan me for a few weeks ?
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heavydriver
post Jan 15 2009, 04:40 PM
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I was grinding away on the floor pan seam when I decided to rip off an undercoating bubble at the right rear corner. As soon as I did it rained rust. You can poke a screwdriver clean through the frame. Is this a common problem area with these cars ? (IMG:style_emoticons/default/post-2-1117899824.gif)

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VaccaRabite
post Jan 15 2009, 04:55 PM
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Yes. (IMG:style_emoticons/default/sad.gif)

Pics of the damage. If its in the long, that is the backbone of the car. Fixable, but an ill omen. Have you probed the hell hole with a screw driver to make sure it is sound? Are your jack points in good shape?

Zach
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heavydriver
post Jan 15 2009, 05:17 PM
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Here you go, one ventilated backbone. The opening goes through to the garage floor. If I clean off the rust can I just leave the hole for future drainage.
(IMG:style_emoticons/default/confused24.gif)

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VaccaRabite
post Jan 15 2009, 06:03 PM
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No, don't leave that open. You will need to clear all the rust of out it and weld it back shut. Most of us have been there and done that (it how I learned how to weld.) Spray the inside with ospho or some other rust converter.

If you leave the open, you will be allowing water laced with battery acid into your longs. When the longs go, your car becomes a donor or a very expensive rebuild.

That spot is the Achilles heel of our cars. Almost everyone has rust issues there due to leaky batterys and pooling water.

I am betting that the fire wall rusty patch will also fold if you probe it. Pretty common. Cut it out and patch it up. LOTS of threads here on it.

Zach
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heavydriver
post Jan 15 2009, 06:54 PM
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Well this alters the plans a little. Next step is to build a jig ala Jeff Hail, it will be good for support and welding practice. (IMG:style_emoticons/default/piratenanner.gif)
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heavydriver
post Jan 31 2009, 03:01 PM
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Small progress. The hellhole wound appears to be small on top but the lower corner forward of the engine mount is gone. The cancer may also be present behind the engine mount. There are some pinholes along the pass outer long, and the lower outer firewall seems to have been repaired a few times in the past.

Questions............

Fix or replace the lower outer firewall ?
Pass long repairable, yes ?

Here is the evidence.......

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heavydriver
post Jan 31 2009, 03:03 PM
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heavydriver
post Jan 31 2009, 03:04 PM
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heavydriver
post Jan 31 2009, 03:05 PM
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tada
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heavydriver
post Jan 31 2009, 03:06 PM
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last for now.
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