Started by going after the reinforcement pieces.
Followed the most common procedure. Cutting the reinforcement in half, right on the seam.

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I now know why no one documents the suspension console removal.
Its kind of like doing a Civil War battlefield surgery.
Who wants to take pictures of that?

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The console has been removed. Had a tough time finding the last few spot welds.

Not in too bad of shape.

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Looks like I'll need a little recreation.

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I was surprised how nice it looked under the console.

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After looking at the wheelhouse. Surprised how bad that corner had rusted.
But I suppose that was the closest corner to the battery vapor run off.

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Off to more spot weld drilling.
Taking off the outer console today.

Hopefully my little tool store will have some 1/4, 5/16 and 3/8 replacements for my RotaCut spot weld cutter. If they don't, he'll order them for me.

They broke because I got pissed that my HF cutter wasn't cutting deep enough. So I tried to recut with the better cutter. Caught an edge and it snapped off.

It looks to be a copy of the Blair. He has Blair replacements for the standard (NAPA,HF) cutter on the shelf. So he can probably get both.

One more cup of coffee and off we go.

Oh yeah,

The replacement drivers long is coming together. And I have another member working on a pair of engine mounts also.

Inch by inch ............. Shooting to be done by the WCR in June.

Nice work!

You are getting there.

Should be good for another 40 years.

John

Thanks John ..............

After the stop at the tool store.

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Last picture shows the broken 3/8 cutter.
The shop was out of 3/8, but I did get the 1/4 and 5/16's.
Spent $20 on each package of refills.
If I remember correct. I think the original kit was about $80.

Here's where we started today ............... Outside half of the suspension console.

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Cart full of weapons .............

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Hah!

And my wife complains when I have 2 a/c grinders, 2 portable drills and 3 or 4 air tools on my tool cart...

I'm sharing your image with her

First reinforcement is removed ...........

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What I found was, it seems its best to cut out the material. Then come back and cut and grind off the weld. The trick being not cut into the piece underneath. Missed a couple spots. But I'm getting the hang of it. Be patient.

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Seems I'm using the cuttings wheels and grinder in all kinds of positions.

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While I'm taking off the outer console.
Super In Law is working on the fit of the inner console to the new inner wheelhouse.

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Well after about 3 hours of work the outer console is off.

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I'm a little more optimistic after I found these two consoles in pretty good shape.

I left the outer console sprayed down with Ospho.

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I'm real happy with the Rotacut spot weld cutter. I followed Perry's input. I dipped the cutter into a cup of cutting oil. Cut the hole about 1/2 way. Blew out the hole and the cutting tip. Then finished cutting the hole. It cut like it was a milling machine.

Real impressive. It was a good day ................

I was thinking today I might need a couple more grinders.
I need both a cutting wheel and a grinding wheel with and without guards.
Might need a couple more Makitas .......

I have a drivers long (Perry), pedal box (Bruce) and a pair of engine mounts (Warren) coming.
Hopefully I can back to work New Years weekend.

Great work, nice to see another car being saved.

Perry's drivers side long has arrived.

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Here it is .................

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Perry did a great job of packaging. It arrived safe and sound.

Dis-assembly begins ...............

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Started with removing the portion of the rear door jam.

Door sill removed ................

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Now getting to the portion that I really wanted to look at.
Removing the longs door hinge support.

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Getting out the leaded flange on the upper portion was a bitch.
But I got ....................

Heres a couple shots of the outer long under the door hinge support.

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As you can see the front fender end isn't welded at all. Well that's not going to work. I'm thinking I'll seam seal it.

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The top only has 2 spot welds.

Bad news for the Tool Whore's wallet.
They just opened a new HF in Hillsboro.

On a side note:

Buying two more grinders. NAPA has a pair of 6 amp Porter Cables 4 1/2 ones sitting on their left over Christmas gift display.

On a sad note:

Being transferred to the companies most outdated and under-performing store. Dandy. Owners explanation. You get paid the most, go fix it.
He had a pretty tough time breaking the news ..............
Start today at 5am .................

You have to wonder, Cary. I found some of that round-section, open-cell construction foam pushed up into this gap between the sail panel and the outer fender panel. I thought it was stock! Seems like there should be nothing in there!!

I thought the same thing.
But when we started the body work on this car a couple years ago. There it was.
I'm sure Scotty, Perry, Jeff and those that having been restoring these cars for years could give you a better explanation.
I think I remember one of them explaining what the factory was thinking. But I can't remember what it was.

My dad just passed away from a fast acting Leukemia. He fainted on Dec 10th. and passed away yesterday. He was 75 and was in what appeared to be perfect health.
They did make an attempt with Chemo, but it didn't work. They say it had a 66% chance.
When you're a kid your dad seems like Superman. It was tough to see him shrink to almost nothing.

Cary
My deepest sympathy to you and your family.

Cary,

My family's condolences on the loss of your dad. Mine passed in 2006 - battled cancer 3 times and won. Appendix burst one evening and the infection took him 3 weeks later, he was 78.

Hang in there.

Dave

Well time to get back to work.
Got my 2 new grinders out of the truck.

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Looks like the last nice day at the man cave for a while. Freezing rain coming tonight.

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I'm back at disecting the drivers long that I bought from Perry.
First I'll cut the long with the plasma cutter.
Could use a cut off wheel. But I thought I'd give the plasma cutter a whirl.

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That was cool. I'll have to get a pair of torch goggles.
Welding helmet is too dark. I couldn't see the line.

Look like we'll have about 100 spot welds to drill out.

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Whoa ............

I got 85 spot welds drilled out with one Rota Cut bit.

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Using Perry's dip into cutting oil technique.
Works like a champ.
Did go through about 5 HF 7/64 pilot hole drill bits.

Hold or clamp a straight edge and burn....

Outer long removed in one solid piece.
Easy deal .................

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Here she is opened up. Looks good.

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Perry gave me lots of material. Looks like I'll have the entire front inner fender portion too.

But the bottom of the long as it starts to go up the wheelhouse will have to be created.
This one is pitted and has a couple holes in the outer layer. Better than mine, but not a good as I want it to be.
That's the section under the rear jack point.

Could do a small patch. But to me, seems that's about the most important section on the entire car.

Had a great day.
Had a tearful moment when Eric Clapton came on the radio.
Tears in Heaven
Took a couple minutes to listen to entire song. Then got back too it.

So back to dissecting the long.
Next will be to remove the engine shelf. I want to remove it totally intact so it could be used in the future.

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Camera doesn't like the halogen lamps......

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Taking off the backend with the end piece attached. No way to remove it without damaging the shelf.

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Got it out in one piece.

Here's the wheelhouse cut off with the plasma cutter.

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Next will be to remove the floorpan portion left on the cut out long.

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Drilled the pilot hole completely thru. That way I wouldn't miss the location on the inside of the seam. Worked great.

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That went real smooth .................easy deal. Still using the second 3/8" Rotacut spot weld cutter.

New weapon rack .................

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I've got it almost trimmed down to were I can start to measure it up for installation.

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Now that I have it trimmed out.
Looks like I'll need a little patch under where the jack point was located.
Plus there's a small one inch crack right by the e-brake indentation.
All in all, she looks pretty good. But won't totally know until I can get it sand blasted.

Hopefully that will be next week.

I've seen several cars with the crack at the parking brake indent. I'm guessing that would be a good place to reinforce ala inner long stiffening kit. Good to hear you are happy with the long. Isn't that Blair tool the shizzle?

Just about the time I think I'll change it. I start a new hole and it goes right to work.

Here's what I hope the final result will be.
The question being, will I leave the trim chrome or powder coat it black?

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Aahhhh, decisions, decisions. Your decision is one I wish i had to make. Keep up the work Cary, this puppy will be beautiful either way!

Looking for some help.............
Went back and re-read Jeff Hail's Dead thread.

When I tie in the new to me part that is double walled. How/can you cut back the existing inner wall without damaging it?
I want to build a new inner box to tie the two parts together.

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Picture from Jeff's thread.

Going to remove the front inner fender from the new long.
That should make the long alignment much easier.

So I hope to remove the front inner fender, and the misc ebrake and center support pieces today. Then hopefully I'll drag out the sand blaster and get the long all tidied up.

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Haven't decided how I'm going to use the the back jtube corner yet. I tore mine up pretty bad when removing the old long.