craaaazzy

iTrader: (9)

wow, so that rotisserie is just like a big engine stand. pretty cool.

woodmv

iTrader: (8)

Wow, that's a pretty ingenious apparatus Mr.lucky80GS, thanks for sharing! I wish I had the space in my garage for one, but I don't and as it is I'm about 1/2 way with the bottom side. I'll keep it in mind if I ever do one again though.

woodmv

iTrader: (8)

Life has gotten in the way of my progress on "rusty" lately. I have an ignition problem on my DD which has put us down to one vehicle, plus maintenance on the other vehicle (my truck). Had to check out the brakes and weld up the exhaust. Not fun, but glad I had the welder. When it rains it pours in my life. At least lately anyway. Seems like when I finally make a little extra money, an extra and unforeseen bill or expense comes up. But, now that the truck is squared away, I can try to get some work done on "rusty" while I wait for Monday to roll around and check out the open recall on my DD. That fix can be anywhere from Stealer pays for it if it's covered by the recall, to $100 or so if I can get it to a locksmith, to $500 to replace with a new ignition, to over $1000 to have the Stealer take care of it. I'm hoping for the option #1. Yeah.

I have had a day or two here and there to get some work done in spurts. Couple weekends ago I took off the rear bumper. After I got it off I was able to find the extent of the previous repair. The lower valence below the bumper is "new". It's been riveted in place and then welded near the rivets. Now those welds have rusted. I'll prolly just wire wheel them clean and hit them with some POR-15 metal prep and primer.









I also found the old "resident". I won't show any pictures of him, but it was as if it were mummified, like he just laid down and went to sleep. I definitely think he had a nice long life. Rest in peace little buddy.

I had the chance to have a buddy come by and look at it and give me some advice about how to repair it all. He's the one that has the professionally restored Camaro. Said it would not be cheap to have the new section grafted in, and suggested I take out only what I must and take it in small sections, so that's what I'll do. I had planned to have his guys paint "rusty" after I was done with the bodywork, but he said I couldn't afford it. Truth is, he's right. I can't...

But, that doesn't stop me from working with what I have on hand. I went to town trying to remove the sections that had rusted through and cant be cleaned up and fixed. I managed to get the long narrow flat piece that goes from the shock tower to the back of the car under the tail light. From side to side this piece goes from the frame to the inner structure of the inner fender.





Once I got that out I worked on removing the inner fender without cutting out the quarter panel....

woodmv

iTrader: (8)

Then I got the muffler off. It's seen better days. It rotted where the inlet is welded to it. The heat shield is a bit rusty and has one hole, but I can fix that easy enough, clean it up and reuse it. I've got the rear hanger in the bucket de-rustifying in the electrolysis bath.

I then got the rest of the inner fender out. I took a good long look at that previous repair with my Camaro buddy, and he said that it ain't perfect but it'll last another 20 years. At least where it isn't rotten. I took wire brush to the rusty welds and sure enough they cleaned up ok. The rest of the inner fender near the bottom - not so much:















The quarter panel is in amazingly great shape. Just some surface rust spots to treat and it will be good to go. The frame and other exposed parts I'm gonna have to wire wheel, grind and clean up and then treat. I definitely have my work cut out for me, that's for sure!

Then today I moved on to the hole in the floor and the rocker panel. Started by taking out a section of the horizontal structure to get access beneath it. This area is right on the structural section where the torsion bar mounts. I'm gonna have to be careful and take it in small sections so that part doesn't move on me...





The piece I took out was in pretty good shape. No major damage, just some surface rust to clean up. It should go back in nicely. You can't really tell from the last pic, but the floor and rocker under the piece I removed have quarter sized holes. Well there you have it. I will definitely take my time with this (have no choice really), but I'll get there one small step at a time. And, with no budget there is no schedule, so that works for me!

PILLC

Rust never sleeps..
Looks like to are repairing it the right way.

rotordogg

iTrader: (4)

At any point do you ever step back and say, "what the heck am I doing?" I give you mad props for taking on this challenge. I for one would have given it up to the rx7 gods and moved on for a rust free version.

woodmv

iTrader: (8)

No, it doesn't unfortunately... BUT, I hope to at least slow it's advance on this to a crawl or fight it to a draw!

Thanks for the props rotordogg! I do sometimes say to myself "this is one expensive free car"!

I have personal reasons to save this one, and I've found that this is by far the worst of the damage on this car so it's all downhill from here! I've learned a lot and have accumulated a bunch of new tool toys along the way. It will be well worth it in the end. I'd like to get it finished and drive it back home and take dad for spin...

Qingdao

iTrader: (3)

Giving electrolysis a whirl?

woodmv

iTrader: (8)

Yep, gonna give electrolysis a whirl on the muffler shroud. The muffler is not even worth saving. Maybe, but we'll see.

Well, back from my whirlwind business trip to San Diego and got some more rust cut out this evening while the repair guy worked on my DD. Word to the wise - don't fly United. Worst. Airline. EVER. Anyhoo, check these pics out:





I popped the last spot weld loose on this piece and the body moved outward ever so slightly, so I pushed it back in with my knee and with one hand welded in the brace to make sure it didn't move anymore.








Here's a couple pics of the floor corner piece that I cut out. As you can see it has seen better days. Best not to drive these things in the snow!




Well, that's all the stuff from the floor section to remove except for the piece I left in on the other side of the torsion bar mount. I guess I can start welding in new stuff before I take too much more out. What's left to remove is the rotted forward section of wheel well, the rocker panel, and the bottom piece that attaches to the rocker at the pinch weld seam (the one that runs the length of the car) and overlaps the floor beneath the car. I may replace the already replaced foot of the B-pillar where it meets the rocker. I love puzzles!

This is by far the worst of the rust on the car. Once I get this shtuff fixed the worst will be behind me! Was is Gandhi that said "the journey of a thousand miles begins with the first step"? One step at a time this project will be done! (insert war cry here).

woodmv

iTrader: (8)

I've been hit and miss with my time on this project, but I've finally cut out most all the rust from the passenger rear wheel area. Not all, but most. One section I have to leave in for now at the torsion bar mount, and the other is on the rear deck near the tail light. I need to get at that.... I have the torsion bar mounting bracket from my donor separated from that section, and after I get the floor in that area rebuilt I may just cut my rusty one out and install the not-so-rusty one.

Here's some pics of the chunks o' rust I've removed:



Yep, rats nest:






Here's the removed base of the B-pillar:


So now I have cut out most all of the rusty sections and have cut out the new sections from my donor. Those pics will be in the next post...

Qingdao

iTrader: (3)

Certainly coming along.

Gotta love the rats. They find the smallest little places to make nests.



I've never flown United (I don't fly much), but I'll keep it in mind. Korean Air is AWSOME. If you are headed to that side of the world for any reason.

woodmv

iTrader: (8)

I've been able to remove the large sections from my donor car. Here's what they look like. Lots and lots of spot welds to cut, which means lots and lots to weld back up!

Here's the donor section as I was cleaning it up:


Here's a comparison between the reinforcing plate around the inner fender / torsion bar mount. You can see some slight design changes between 79 and 84/85, but the biggest difference is the FREAKING HOLE CAUSED BY RUST:


Here's the removed inner fender section comparison - the replaced section from whatever body repair had been done to my car, and the section I took out of my donor car: Amazing the difference!




So that left me with the quarter panel section and the frame section which I separated and have tucked away in my shed for future use if I ever need them. You never know!




I'm soaking the inside piece of the inner fender in the electrolysis bath because the reinforcing plate (already electrolysized) and the fender were a bit rusty, but not through and not spread too far. Seems like that is a very common area that is prone to rust, because even this "rust free" donor section was rusted a bit.

So that's where I'm at. Need to finish prepping the area to be welded, the pieces I'm gonna weld in, and trim them up to size. I need to get one of those flanging tools. Saw one at the local flea market a few weeks ago for $4. Wonder if it's still there....

woodmv

iTrader: (8)

I need a sign like that at my garage door! Been busy with other commitments lately, so I get on this as and when I can. Got the new inner fender welded in. The biggest piece to replace. I cleaned it up and hit it and the inside of the quarter panel, as well as the rusty frame that I ground smooth with the metal ready and POR-15 and let it sit for a couple days, then tek-screwed it in place, then welded. Not a lot to look at, but it's better than it was and slowly getting rebuilt!

Enjoy the pics!

















My welding skills still leave lots to be desired, but it is what it is, and that's better than it was! It ain't pretty but it's getting done. Step by step, inch by inch...

82transam

iTrader: (18)

Haven't checked this in a while and DAMN you might be more insane than I am with this. That is a ton of work sir!

Looking good though

woodmv

iTrader: (8)

Insane in the membrane... Yes, I have an obsession with removing the rust on this car. Plus, it's a learning adventure and I have to make hay while I can. So tonight I prepped and mocked up the base of the b-pillar after work. Was hoping to get it welded in tonight too, but no dice. Need time for the weld thru primer to dry.

I decided I'd make a backing plate of sorts for the seam on the inner fender where the two sections will meet at the cut line. I have a really hard time butt welding with this thin metal without having a bunch of blow throughs and creating more of a nasty hole than actually filling in a joint. I haven't perfected that technique yet, but if I have thicker metal to weld to I can lay down a better bead that gets good penetration without blowing through the metal. The welds aren't pretty, but they are better. So that backing plate fits up behind the other piece of the inner fender that I've already welded in. Again, not pretty but effective.

Here's the prepped up b-pillar base with the backing plate welded on:






Here's a comparison of the old rotten b-pillar base and my nice new one. You can see on the new section there are five factory holes punched in there. Two of them on the old section have rotted out:


And here it is mocked up inside the car. Can't wait to weld this beyotch in. Feels good to be making progress putting it back together rather than tearing it apart!

Ausssierx7kid

Awesome read man, good luck with finishing it!

woodmv

iTrader: (8)

Thanks Aussierx7kid! It has been an adventure for sure.

Well, I've been hit and miss on this for the last couple weeks, but have managed to make some progress. I was able to get the B-pillar welded back in and a large section of the floor. I thought I was getting better at making the welds penetrate good and make a nice bead that cools more flat than like a bubble, and I was, but looking at the finished product the word "meh" comes to mind. The welds aren't the prettiest in the world but they are strong. I have a couple pin holes to weld up, but it's getting closer to done in this area. Enjoy the pics:











Had to cut out an additional small section of the floor because it had some pinholes and pitting on the inside of the rocker. I created a flange with a pair of pliers and a hammer using the frame/deck of my chop saw as a dolly. I never did make it back to the flea market to pick up those flanging pliers...


Then I set out making patch panels out of some of the removed sections that weren't rusty and the one good section of firewall I have. Needed a 2" by 10" section that I fabricated, well, not really fabricated so much as cut out of the removed floor pan section from the drivers side which I flanged and contoured to match.










So, like I said, the welds aren't very sexy but they are strong, and in this area strong counts. I'll have to really practice a bit more when it comes to welding the outer rocker replacement piece in. I have that piece, the inner wheel well, and the small narrow flat piece of the rear deck to weld in and I will be done with this side of he car. I'll prolly drop the tank and see what's lurking behind it (fingers crossed) after I finish this section up, and then move on the to the rear drivers side. It isn't as bad as the passenger side was, but is bad nonetheless. I have a large section of floor to replace in that area too.

GySgtFrank

iTrader: (4)

You are one determined ***.

One heck of a learning experience. Will you have any of the original car left when you get it all done? At least you will know your car inside and out... intimately.

woodmv

iTrader: (8)

Thank you! And yes, I am determined! I'm shooting for as rust free a car as possible with my limited budget, tools, skills, and knowhow.

I burned a day of leave and rock and rolled on this rear passenger side the other day. Got the new inner fender section welded in. There are definitely some design differences between 79 and 85 (or whatever year this donor car was ... 84 maybe?). The punched "D" shaped hole at the trailing suspension arm, as I pointed out earlier, is a bit redesigned. Well, this sits about 1/2 lower than the control arm mount on my car. It isn't too much of a problem though as the bolt will go through ok. It's just a minor sheet metal alignment problem that I can live with. I'll take that over the giant rust holes any day...

This new inner fender also doesn't quite match up to the sloped surface that is the bottom of the car underneath the pan where the bins on later models resides. You can see the holes from the cut spot welds on this surface in some of these pictures. I made some new holes of my own and welded it up. Just need to fill these holes, and one bullet hole that I found in the inner fender!

Here it is tek screwed into place. Maybe the alignment of the sheet metal has something to do with the fact that the car had been hit before... But I doubt it because the frame isn't bent, so I think it's just slight design or manufacturing differences between the years. Close enough for me though!


And welded into place.






Looks a LOT better than rusty holes!!!




Now I have to fill in some holes, fix/weld the seam along the sloped edge underneath the "bin area", grind and seal the welds with POR-15, seam sealer, undercoating and viola`! New-ish passenger rear wheel well! I'm digging getting towards a rust free body!

woodmv

iTrader: (8)

I think I have finally licked most of the rust on the rear wheel well and gotten it all back together. I got the rest of the welding done, painted the new welds with the last of the POR-15 I had (silver in color), sealed the seams, let that stuff dry a few days, primed over everything, and sprayed the wheel well with the undercoating. I ran out and need to get more to finish the job, but aside from a section of frame that I need to grind some rust off from and repaint, this car is about 3/4 rust free!

Here's some pics of my progress:

woodmv

iTrader: (8)

Here's some before and afters to show just how far gone this section of the car was and how new-ish it looks now:

Passenger side rear wheel well:







Looking forward at end of rocker panel / floor behind passenger seat / front of inner fender wheel well:







Looking up at the floor near torsion bar mount:




Looking back towards rear side of the wheel well:




Like I said, I have a bit more work to grind off some rust from the frame, treat it, and repaint it. Then it's on to the gas tank and rear drivers side wheel well and b-pillar, which is bad, but not AS bad as this side was.

woodmv

iTrader: (8)

Here's what I have for the driver's rear wheel well area. Glad I know how this goes together now!













I drew out, or rather scratched out, some cut lines, and this section is a LOT smaller than the passenger side!

88fc3sT2

iTrader: (1)

Yikes! That thing was rotting big time.

andernamen

iTrader: (2)

With all your experience doing this, you will be ready to help me with mine! Lucky for you, it isn't as bad as yours....yet!

woodmv

iTrader: (8)

And I hope that it remains "WAS" from here on out...

Sure! That'd be fun if I can squeeze it in. I'd prolly be best utilized as a consultant. I have no problem tearing apart my stuff, but when it comes to other peoples' stuff I hate to take the chance of damaging it or their tools. But consultant and maybe the tool and beer fetcher/passer, sure!

Tore into the drivers side wheel well and B-pillar area tonight. Looks vaguely familiar...













Going a bit quicker this time though and I'm not gonna tear out the entire inner fender this time.