I am in absolute awe of this bulkhead patch. Love seeing the progress. Thanks for posting.

Let the welding begin.
Series shows 1/8 Cleco hole. Then outer layer enlarged with sheet metal cutter.
Then rosette welded.
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A couple more rosettes.
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Still need to back off the trigger 1/4 to 1/2 second sooner. Some day I'll get it.

Bottom welded, finished up and galvanized.

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Selfie
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Slow going. 36 degrees and raining in Forest Grove. So only out there 6 hours a day.

Dash welded back to the bulkhead.
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Steering column support welded back on. Removed to aid in the flexibility of the bulkhead.
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It takes a pile of tools to get the fit and finish I want.
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Next on to the right inner fender and fuel tank cavity.
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That lower section tough to fit. And tough to weld.
Next onto the air vent holes to the cowl/door frame. Right will get a new piece all together.

Left side air vent sheet metal is just about worthless so out it comes.
Super In Law is creating the 2 piece large patch.
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I start by cutting out a section that was a little short.
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Bottom

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Top

Then on to repairing the left side.
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Patch #1
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Patch #2, a little tougher, curved in the middle.
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Had to make in 2 pieces, too small to create in the beater bag. Bent the flange with the
hammer on a RR rail piece.

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Time to go home.

I need a bigger hammer.
https://www.trick-tools.com/Scotchman_50514...r_50514_CM_1886

The monstrous tasks you hard-core metal guys take on and complete is absolutely amazing

... but it also make me feel good about the near rust-free cars I've been fortunate to own

Keep up the good work

Been a while. Been working on mechanical projects.
Back to finishing up the welding in of front chassis bulkhead. Corners up against the hinge pillar got pretty tore up during harvesting.

Finishing up the right side.
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Inside the fuel tank cavity

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Above the passengers knees

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Tray was empty when I started.

On to the left side that has its own set of challenges.

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No flange

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Vent section didn't survive.

Time for a little catch up on Taylor's car.
The bulk head is finally finished.
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Now the question lies. Will I attempt to save another bulkhead from
the parts car outside ? Would I ever want to do another one ?

I wouldn't have the guts to do the first one so whatever you decide, you are a far better man than I. Unbelievable work there.

With the bulkhead completed its time to address the tail light panel.
Lots of owees.
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Looks like some one made an attempt to remove the tow hook. Or its a half ass attempt
to remove the stress from collision damage.
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Plus it looks like it was backed over something. That corner already has been patched.
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But in order to work on the tail light panel it has to come off the rotisserie.
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But on a positive note, like I mentioned on Instagram. The chassis dolly is actually
our old chassis jig converted into a dolly. Other than a couple taps with a hammer
it bolted straight in. So from the trailing arm mounts to the rear steering rack she's
5 * 5.

Another shot of the panel. Mark has a used one that I'll attempt to use after its stripped.
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Surgery center all set up for my return in a couple weeks.
Vacation with wife.
8 day commitment at Rothsport
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Labor of love .................
Super In Law straightening the folded over qtr. corner .
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Last couple issues before it heads home or to the body shop for mud and paint.
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Trunk for too bad. It has some PO cuts and holes that can be patched or filled. But the
left side of the tail light looks like it was beaten too death. In the essence of time I only cut out the beat to death section.
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Out it came and in in went ................
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Not quite that easy. But you get the gist of it. A lot of measure 10 times, cut once.
Then blip, blip, blip.

Donor piece has had some love in the past but should be ok.

Making some progress.
we used tint-able truck bead liner and made it the color of the car. shot it and let it cure for about 12 weeks (no intentionally, just didn't have time and the weather to press on.

Taylor was sanding and prepping the rest of the shell for the epoxy primer we shot today.

Did make a few mistakes. Realized we needed seam sealer in a few places is the big one. That and a little learning curve with the gun, but we have sand paper.... lots of sandpaper.

Plan to shoot the interior, windshield area, and the engine compartment so we can begin putting the engine, suspension and interior back in. Will shoot the rest onece most of the assembly work is done.

And the artsy shot
It was a nice day today!

Looking good there....

I was actually up at Timberline lodge with the wife and twins today (Feb 19), but the weather was identical to you pic. 25F up there and sunny. Fun day. Nice to be able to drive there from our house in just under an hour.

Good progress, Great view from the shop...

Taylor laid some paint down in the areas that he needs to reassemble and will not be accessible once stuff is in.
The fun is about to start.

more

more

and more

and where we will be starting

Looking good ...