Monday the right fender will get a close inspection. No holes per say, but quite a bit of degradation. Might be ok.

Labor Day 2017

Taylor will be laboring to remove the remainder of the inner fender from our pedal box firewall patch panel.
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Started Labor Day doing my least favorite task, outdoor media blasting.
I blasted the lower portion of the front firewall that we'll be using for our patch panel.
Hopefully it made it easier for Taylor to remove the spot welds.
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I got the fender patch welded in. I did it from the inside so I wasn't fighting the cowl.
I did a couple test sections of smoothing the weld from the top side. Looks like they finish up real nice.
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Taylor did a nice job of removing the trimmed off fender portions and hammered out a wrinkle that we didn't see originally.
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Here's a shot of where we're at on Taylor's car . Your looking thru the targa bar down into the front firewall and into the frunk. The panel had to be seperated to be installed.
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Everything is kind on hold till I finish up Doug's project and or add another welder to the shop. Super In Law gave Taylor a MIG welding lesson and he's been tuning up the spot weld cutter holes on the parts we're going to put back in the car.
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Wow, You dont see that too often! Rarely does the front firewall have to be removed...

Great looking project!

Yes this was a almost rust free car. Otherwise this would be a parts car.

Man, this is not your ordinary restoration. Keep up the great work!

Ah you forget it was a parts car, a very good parts car at that. With the amazing work going into her she’s looking more everyday like the day will come that she’s reborn as new. Great amazing work you’re going to end up with a very nice car to be proud of.

With Super In Law awaiting his release, its time to get back to work.
Kind of stuck finishing up Mike's transmission swap and engine freshen up.
The mounting stud on the Pertronix was loose so Mike took it home for a JB Weld repair in a heated house.

So it's time to bring Taylor's project out Front and Center. It's a little chilly in the Non-Heated portion of the shop, but I'll push thru it. Cools the tack welds faster, LOL.

Getting off to a chilly start ..................brrrr
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Started with grinding and sanding the seam welds. Then onto welding up all the spot weld cutter holes.
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Needs a little and dolly work. But turned out pretty good considering where we started.
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As long as was there I tuned up the door frame / tub wall.
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After a little more inspecting ..................

I found the left front sway bar mount is missing a nut and torn.
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Used my Tangerine backing plate to center it up and weld on an 8mm flange nut to
put it back in business.
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Then it was time to take a look at the front trunk channel.
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I'll probably move this repair to a separate thread because I'll be using the 914 Rubber's weatherstripping channel repair strips.

Next it was time to cut out the right fender pee pee holes.
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Here's a few shots of the pee peed metal.
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Thanks Cary,
Looks like it was a little worse there than we thought, but a t least we will have it fixed.

Got all bundled up and got back to work. Still 40 degrees ...............
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Out came the right fender..............
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Trimmed off the excess on the new patch piece. Then clamped it up and cut out the patch to fit.
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Got a nice tight fit on the patch. I was thinking that I made the patch too big. But I still ran into some thin spots along the seam.
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Let the fun begin ..................
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Welding was pretty uneventful ............ other than the thin spots I'll need to tackle in the morning.
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I love my MillerMatic 141 ....................

Good news is it's supposed to be warmer tomorrow.
Mark

Started with tidying up the thin spots created by the round material and over finishing.
Tough sledding on the round surfaces.
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Then on to filling all the spot weld holes and 40 years of PO sheet metal holes.
Had to make a couple patches on the cross member arch.
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Handy tool

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Took a while but got them ready for the next step. Didn't over finish too much. They'll get spot or rosette welded again.
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^wow, great sheet metal work there!

man, i love to see a car being blasted right down to metal, nice

It costs. But it's the only way you find everything.

This is my gift to my son. He puts in the time, I put up the cash ...and parts.

Next was the tune up of the hinge support and dash tie in.
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Yes, the blasting glass continues to fall out of the long ...............

After close inspection I decide the floor/firewall/chassis tie in braces need new flanges rather than trying to fill in the damage done by the spot weld removal.
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Went to Rothsport today and stomp sheared some 1/2" 20ga strips.

Then it was time to start the fitting of the replacement fuel tank/firewall lower portion.
It's going to take some time determining the cut out. Nothing was left of original section. It came out in pieces.
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The lower section of the fender/fuel tank will be installed after the section above.
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Forgot to post Sunday's work.

Started the day by seeing if I could shrink the 1/2" strips I sheared at Rothsport.
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We'll come back to those later ................

Next onto the seriously dented cross-member mount.
I decided the mount would have to come off first so I can pound out the dent.
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That's supposed to be flat .....................
I'm surprised Jack didn't catch it when he dropped the front suspension.

Off she came.
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Ended up with an oil can dent inside the orange lines. Tried to move the metal too fast.
Needs to be in the car and solidly attached. Shrinking hammer was enough. I'll fire up the shrinking disk after the patch panel is solidly welded in.
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Then it was time to start fitting and trimming .................
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Here's the bottom of the cross-member mount dent.
It will take some tuning to get the edge to line up correctly.
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Then it was time to fill all the spot weld cutter holes.
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Let the fun begin. Tuning and tacking ................
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Got a good start before I headed home ................

Thanks Cary,
See you Wed with some cash.

Friday didn't quite go as planned so I went back to work on Taylor's car.

Finished the stitching and got the front seam welded in. Didn't over finish the bottom. It will be under coated. The top side finished up real nice and its ready for the wall section.
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Then it was back to the oil canned section next to the fuel tank access hole.
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The little shrinking disk takes quite a long time to get the metal heated up. Or maybe its just cold outside. With the front attached I got about 80% of it out.

On to the passenger floor seam .................
With the front tied down it allowed me to pound it down flat. As it flattened out I trimmed a couple more mms out between the 2 pcs as I went along. Saw blade width.
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I even retained the drain slot ...............

6 inches to go on the back side. I have a piece to trim down to replace the section that got scalped during cut out.
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Getting an early start. Want to get this section finished up. Plus waiting for a reply on a wood/metal upright band saw on Craigslist.

Got the tip welded back on ...........
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After test fitting Doug's old cross member it looks like we have a little issue.
I'll do some measurements tonite to see where we're off. I have the car on the frame bench to measure against.
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Yes, I could make it fit. Bigger Hammer. But I don't want to use up our given +/- tolerance with a hammer.

Doug's mount fits into my project car, like butter.
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Taylor brought out his cross member and it fits like Doug's so we'll go with that.

Odd thing though. The cross member we'd set aside for the frame bench fits into Taylor's car as is. Who knows ......... They should all fit the same ............. Strap(s) tweaked.
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Well I went to the geometry expert for some input. Rick 918-S.
Best guess is that the car took a bump to the right torsion bar tube end.
I'll take some more measurements in the am to confirm. While we're measuring and coming up with a plan I'm going ahead with the front channel rust repair.
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I'm going to cover this in a separate thread. Because ................
Mark and the team at 914 Rubber are going to make the replacement pieces available.
But looks like I need to get some measurements to get some complete channels made up.

Nice work Cary. It's always interesting and challenging when it comes to chassis diagnosis. Specially with 2000 miles between us. Looks like we figured out what happened. I have a few ideas how to set it right. I will send another email then we can talk again.

Such a great community....

Well after all the measurements, pictures and emails Rick and I came to the consensus that the car took a hit on the right control arm end cap and tire wheel.
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pretty significant whack..................
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But after all the geometry, it looks to be 2-3 mm both back and to the right. Which is just a smidgen out of tolerance. So back to work ...............

First order of business. I'll fix the split in the tire well.
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Needs a little more hammer and dolly work when I have a second set of hands.

Blasted the cross member and gave it a couple coats of cold galvanizing.
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After just a smidgen of tuning and she slipped into place.

Next onto welding in the right rear cross member mount.
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Always enjoy a challenge.

Here's all the geometry ..............
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For prosperity's sake, I'll double check my notes on the 498.

Back to work ............

Spent the morning weldng on the right rear cross member mount and re welding the arch. A little dicey ........... The flange took quite a beating coming out. But it came together nicely.
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Checking the backside ............. a couple pin holes to fill

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Gooder as new .......

Left last night with the bottom side of the cowl getting an Ospho treatment.
Best guess is the rust freckles are from the Dustless Blaster media left hanging.
Prior to the treatment, Taylor spent about 3 hours removing blasting media from the tub.
Round and round on the rotisserie. Plus some tapping with rubber mallets.

Finished up the left side arch yesterday.
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Next is the bottom 1/2 patch piece on the strut/fuel tank trunk wall.

Catch up on Taylor's car.
1st. Treated the bottom side of the cowl with OSPHO. It had quite a bit of over spray or condensation from the paint stripping. After the OSPHO dried Taylor scrubbed it down with a red pad.
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Then I gave it two coats of cold galvanizing in case it gets missing during paint.
Forgot to shoot a photo. I'll be back.

2nd. Onto the patch at the base of the cross panel.
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Took a little tuning to get it ready to weld in. It's a pretty tough removal. It's wedged in there pretty good.
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Ready to go ................
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Decided that the left inner fender needed a patch on a fairly thin spot.
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Have not been very active on the forum but still making progress. Don't have any pictures of before or during, but spent the weekend tearing out the rotted suspension. Now for some patch work and the me part us ready for install. Click to view attachment kooClick to view attachment

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I feel bad. I've been so busy in the other room working with Matt. I haven't taken any pictures when go out and answer Taylor's questions. He did a great job on the suspension console removal. Looks like we'll have a little skin transfusion on the outer layer of the upper long.

Some good progress was made this weekend on firewall patches. Click to view attachment

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Prepping the donor. Click to view attachment

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just ordered up the passenger side engine tray section from Restoration design. Next week ready for install, maybe???

Amazing work, turned out the car had more rust than I found when decided it was a Parts’s car.