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Old 02-10-2013, 07:48 PM   #61
JTurbo
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Now the rust removal from the bottom of the door:


remove the garbage:


Weld in new metal to the frame:

New metal to the skin:

Treated the frame with rust encapsulation / prevention primer:

Also have to deal with the hole that isn't required for the power accessories:

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Old 02-10-2013, 07:50 PM   #62
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Next project:
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Old 02-13-2013, 09:52 PM   #63
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More work to the driver side door:



Here you can see why I need to graft a section of the old door frame into the aero door. The window guide track needed the structure for the lower bolt:


T-top doors have an added brace along the top edge on the inside:



So all the structural repair work is done on this door. Working on the plastic now so no updates for a while.

JT
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Old 02-24-2013, 08:47 PM   #64
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Good weekend, got the major body work complete on the driver side and in primer:



Yesterday was a good day to be in the garage, was rainy/snowy/crappy:


And tonight I got the guts and glass into the driver's side door:


It helps to have the passenger side door as a reference

Tomorrow night I'm going to spin the car around and start the plastic work on the passenger side......

JT
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Old 02-28-2013, 02:35 PM   #65
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You just amaze me bud with your skills!!!
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My Rides - Past and Present --- My FQuick Garage
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Old 03-05-2013, 08:39 PM   #66
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Thanks Jeff!

Last week I spun around the car and sanded down the fender and door:


Progress this past weekend, focused on the passenger door, stripped the glass and guts from the original one and installed on the new one, including the top support bar that needs to be welded:



Here is where it's at. At least now I can sand and not get a bunch of dust/crap inside the car now.


JT
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Old 03-09-2013, 10:28 PM   #67
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Plastic work done, primer is coming....



Was also sanding down the hatch.
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Old 03-09-2013, 10:29 PM   #68
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Passenger side basically complete.




Work done so far on the hatch:


JT
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Old 03-17-2013, 08:23 PM   #69
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Last weekend I backed the rotter out of the garage so I could give the garage floor a good cleaning. And while it was out I threw some more parts at it:



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Old 03-17-2013, 08:25 PM   #70
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Sanded the hood down and then used the stud welder on some dents on the hood:


Then hit the minor surface rust with Eastwood's rust converter:



Then I pulled the front end assembly from under my deck and removed the head lights and separated the lower valance from the upper bumper. Here is the lower:

Going to need A LOT of repair work:

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Old 03-17-2013, 08:27 PM   #71
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Had to replace 5 of the 6 studs in the header panel where it bolts back to the fenders. Used JB Weld and made sure that the nuts spun freely to aid in re-assembly when I bolted the header back to the fenders.

Was nice to finally get the nose back on the car



Had to fix the mounting hardware that is used to fasten the lower valance to the bumper support. The original studs broke off, so I removed what was left from the old studs and welded in new 1/4-20 carriage bolts:

Here is the set of 4 completed:
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Old 03-17-2013, 08:29 PM   #72
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Got most of the front nose sanded, first coat of plastic on the hood:

And finally, the hatch kicked my butt, took a lot of work to get it smooth/flat....


That's all for now

JT
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Old 03-24-2013, 06:22 PM   #73
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Removed the windshield yesterday:

And I got it out without cracking it

Reason for removal:



The reason why I continue to call this car "the rotter"

Where I'm currently at:

Took a break today from the car. Temps were up a bit, was nice to wash the daily drivers. I'll do some more cutting this week and start to weld in some patch panels.

JT
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Old 03-29-2013, 12:34 PM   #74
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Removed the "thin" metal:

Started to fab up a patch panel, there are three separate pieces here:

Patch ready to be welded in.

I'm planning on welding in a few tabs underneath the patch for a bit more strength and to make the patch easier to weld in.

No updates until after Easter weekend.
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Old 04-30-2013, 06:30 PM   #75
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Here are the latest pics:


Next repairing the roof skin:


All the welds ground down:


A little bit of filler:

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