Category Archives: metal fabrication

NEED A LIFT

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There are certainly times when every shade tree mechanic could use a big commercial lift. It sure was on my wish list as I crawled around under the mustang trying to install the new dual exhaust. I just can’t help wondering how much easier it would have been with the car more than 2 feet off the floor.

 

Anyway, I had the parts for the new dual exhaust and the job had to be done. The old exhaust came off without too much trouble. I wanted to paint the new kit but first it needed to be test fitted and marked.

H-Pipe

I started with the H-pipe naturally since it bolts up to the stock manifolds. Yes, I still have the factory cast iron manifolds. Why, you may ask. Because you don’t need headers unless you’re building an engine with all the power in the upper RPM range. For a little street V8 the stock headers are fine and they give you nice low end torque. So, no need for headers on a 225 HP 289 v8.

You might also be wondering why I didn’t paint the pipes first and then install them. Firstly because I wanted to weld all the connections and I hate having to try to sand off the paint to get a good weld and secondly I wasn’t sure how much modification I would have to do to this kit. So I test fitted and marked all the pipes before painting them.

Connectors

Then the connector pipes were fitted and marked.

Muffler

Then the mufflers and tailpipes were fitted. Then it was all removed for painting.

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Above is the exhaust kit being painted with high temperature paint. Stainless pipes would have been nice but they were just too pricey. After the paint dried I put everything back on the car and clamped it up and took it for a test drive. It sounded good and everything seemed to be in place.

Overall the exhaust kit fit very well and the only problem with it was that the tail pipes were a bit too short for the stainless tips I was using.

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I had to weld some extensions on to bring the tips out far enough. No big deal, just a little more time crawling around under the car. I also welded up the other joints to eliminate leaks.

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The exhaust looks nice and sounds nice. Although after a test drive the tail pipes shifted just a bit so I will have to go back and sort that out to keep the tips centered up.

 

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SHE RUNS!

OLYMPUS DIGITAL CAMERAI cleaned up the spindle and control arm and stuff and gave it a little spray paint. It doesn’t look great but it looks better than rust. Hopefully in the future it will all be replaced with new performance parts.

OLYMPUS DIGITAL CAMERAThe backing plates cleaned up nicely.

OLYMPUS DIGITAL CAMERAHere is the brake assembly with new wheel cylinder. It turned out to be much easier than I had anticipated. I guess I’ve done these old drum style brakes so many times it’s just second nature now.

OLYMPUS DIGITAL CAMERAOnce again, it looks better than rust.

So after getting the front brakes finished and replacing a coupling in the brake line the car was finally safe to drive. So I drove it. It ran stinky and it overheated again. So I ordered a new aluminum radiator.

OLYMPUS DIGITAL CAMERAI like the new radiator. It’s shiny.

OLYMPUS DIGITAL CAMERAAnd it cools much better. It hasn’t overheated yet but it does start to get hot after idling for a while so I ordered a fan shroud. I’ve been driving the car around for a couple of days and sorting out little things. I spent a couple hours yesterday welding the leaks in the exhaust system. I got it pretty well sealed up but the mufflers are junk so it’s still too loud. The vacuum advance is still not working right but I’ve decided to replace the entire distributor and coil and put in an electronic ignition. That will probably be my project for next month. But right it it’s drivable and that’s a good thing. So enjoy a few pictures of the road ready mustang.

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GIVE ME A BRAKE

OLYMPUS DIGITAL CAMERAGetting this thing back on the road has been a little more challenging than I expected. After all, I drove it home 60 miles when I purchased it. Now I can’t get it out of the driveway and into the street.

When I last posted the car needed a water pump and I thought it might have a blown head gasket. I put a new water pump on and the overheating seems to be under control although I still want to put an electric fan in front of the radiator to help at idle. I’m also happy to report there is no blown head gasket. After a bit of tinkering I was able to diagnose the engine problem as a faulty carb.

OLYMPUS DIGITAL CAMERAOnce I made the diagnosis I decided to take it off and dissect it. As you can see it had a bad case of the cruds. Rather that spend more time and money on this old carb I decided to get a new one. I got the Holley 650 with electric choke. I hope it’ll get a little better gas mileage than the old one. (I wasn’t even sure what size the old one was)

OLYMPUS DIGITAL CAMERASince the carb was off I thought it would be a good time to clean up the old intake. After a little cleaning and some paint it looks like new.

OLYMPUS DIGITAL CAMERAThis is the new Holley 650 installed. Putting on a new carb solved the horrible running condition but there was still a problem with the vacuum advance. I checked the timing and wanted to adjust it but wouldn’t you know, the distributor was all frozen up in the block. It took a week of soaking in PB Blaster to get it loose. I was able to get the timing adjusted right but the vacuum advance is still causing a problem. As soon as the timing starts advancing with the vacuum advance it looses power and dies. I put the timing light on it to watch as the timing changed and at a certain point the power cuts off and the timing light goes dead and the engine dies until the advance decreases. Weird huh? I checked the plate in the distributor and all the point wires and everything looks normal. I disconnected the vacuum advance and it runs fine. I’ll just run it without vacuum advance until I can get it figured out.

Since the engine was running fairly decent again I thought we were ready for a little cruise. Caroline and I jumped in the car but we didn’t get far. We didn’t even make it out of the driveway. The brake pedal got mushy and I could barely stop the car at an idle. So back in the garage it went.

It had the old single bowl master cylinder which was so rusty I couldn’t even get the lid off to check the fluid level. I decided to order a new dual bowl master cylinder. Those things aren’t cheap anymore like they used to be. Anyway, it came in and I put it on and guess what? Still no brakes. So I pulled off the front drums to check the wheel cylinders.

OLYMPUS DIGITAL CAMERAAbove is the culprit. I pulled the rubber boot and rusty brake fluid poured out. So I have some wheel cylinders on order. Since this is going to be another whole project I thought I might as well restore everything.

OLYMPUS DIGITAL CAMERAThese old parts cleaned up OK. No need to buy a new hardware kit.

OLYMPUS DIGITAL CAMERAThese cleaned up good too. The brake shoes look almost new.

OLYMPUS DIGITAL CAMERAThese are in progress.

OLYMPUS DIGITAL CAMERAAnd this still needs to be cleaned and painted. Maybe it will make it out of the driveway by Christmas.

ATTITUDE

HeaderAnother super busy weekend has reaped a few rewards. I’ve had a couple of projects that have been hanging over my head for a while so I decided to go ahead and get them over with.

OLYMPUS DIGITAL CAMERAI pulled the car out of the garage to make room for my projects.

OLYMPUS DIGITAL CAMERAThe hood had been bugging me ever since I painted it. The paint was light and splotchy on the sides and worse than that, the stripes on the back end didn’t quite line up with the stripes on the cowl. It was just driving me crazy every time I looked at it so I took the hood off and started sanding it down for a repaint. The underside of the trunk lid needed painting too so I thought I’d get it all done in one long day.

OLYMPUS DIGITAL CAMERAYou’ve seen something like this before. I’m in the process of masking off the silver stripe here.

OLYMPUS DIGITAL CAMERAHere it is after color and three coats of clear.

OLYMPUS DIGITAL CAMERAAnd here it is after wet sanding and polishing the clear. Everything lines up now and there are no light splotchy areas. I can rest easy now.

OLYMPUS DIGITAL CAMERAThis is the underside of the trunk lid all painted and ready for weatherstripping and hardware.

OLYMPUS DIGITAL CAMERAAfter finishing the hood I got down to installing the gauges. I need to know if the engine is trying to cook itself. I think it may have some overheating problems. I haven’t run the engine long enough to check for overheating since I installed the gauges but the oil pressure is very good and the volts are good so that’s a relief.

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Oh yeah. I also painted the air cleaner cover. It was black and crusty and I just couldn’t stand looking at any longer. As you can see I haven’t done anything else with the engine compartment yet. I plan on painting the valve covers to match the body color. Eventually when I yank the engine out I’ll do the whole compartment right.

After I finished up mounting the hood I thought it was time to give the front end a little attitude.

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Nothing adds a little attitude like hood locks.

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WORKING? YEAH, LIKE A DOG

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Some folks might think I’ve been goofing off because it’s been a few weeks since my last post. Actually I’ve been working so hard I haven’t had time to take pictures and post them. Much has been accomplished and the following pictures don’t truly portray the amount of work that has gone into the car.

After finishing the headliner I decided to put the new windshield in. It’s a gasket windshield which means you put on a big rubber gasket first and then, using 12 gauge wire, pull the windshield into the frame. Of course you have to use sealers and such but it’s actually a simple process.

OLYMPUS DIGITAL CAMERAAbove you can see the windshield right after installation. This was one of the easier projects on the car. The trim was actually more difficult to install than the window.

OLYMPUS DIGITAL CAMERAOne very important step when installing the trim is to mark the trim clip locations with tape. That way you know right where to push to clip it in.

OLYMPUS DIGITAL CAMERAThe photo above shows the completed windshield and trim installation. And that’s all there is to that project. The whole thing was only about 3 hours I think.

The next project on the list was the new heater core. Earlier I had restored the heater box so now I had to take it apart again to put in a new heater core and add the new defrost plenum and ducts.

OLYMPUS DIGITAL CAMERAAbove you can see the old heater box and the new core.

OLYMPUS DIGITAL CAMERAI bought new rubber end seals which had to be modified to fit. With some patient trimming I was able to get a real nice fit.

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And here we have the core as it fits in the box.

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After some careful assembly I dragged out the heater controls and got some new heater hose and got the whole system mounted up under the dash.

Next project – Radio, speakers, and dash pad.

OLYMPUS DIGITAL CAMERARemember these? It’s an old Pioneer Super Tuner. I think it’s from the eighties but it still works great. I put the old dry rotted pioneer 3″ speakers back in the dash where they came from. I was going to toss them but when I used them to test the radio I found they still sounded pretty good.

OLYMPUS DIGITAL CAMERAI got some Sony 6 x 9s (from Walmart) for the back. I still have to make a new panel but I have to get the rear window installed first. So that takes care of the sound system. If nothing else works on the car at least I can sit in it and listen to the radio.

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After the heater and radio were done I was able to get the dash pad fully installed with all the stainless trim. I just love the design detail in the 65 dash.

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Oh yeah, I put in a new glove box and put the glove box door on too. I even got the little glove box light working. So right now the only thing on the dash that’s not hooked up yet is the cigaret lighter.

Next up – Window tint.

OLYMPUS DIGITAL CAMERAI was going to take all the windows someplace and have them tinted but the shop I went to didn’t want to touch it. They said it was too much of a pain to do these old windows with the trim around them. So I had to do it myself. Window tinting is easy if you can keep everything clean. Unfortunately that’s impossible with these old windows with deteriorating gaskets. No matter how many times you clean them little particles still come out as soon as you spray the window and put the film on. So it’s virtually impossible to get a perfect tint with my old windows.

OLYMPUS DIGITAL CAMERABut from a few feet away it looks very nice. Another key thing when tinting is to get the tint cut exactly right with a tiny bit of space around the edge. By the time I did the last window I had it all figured out.

OLYMPUS DIGITAL CAMERAI used a 30% tint which is not real dark. I’m getting a little old and I want to be able to see out the windows at night. When I was young I would have used about a 10%.

OLYMPUS DIGITAL CAMERAThe trickiest window was the back one. I had to heat shrink the film to get it to fit the contour. I had never done it before but I watched a few Youtube videos and was able to get it done on the first try.

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Above is the quarter window installed. I also installed all the weather stripping and trim. Getting the window put back together took a little time and several tries since I had forgotten how it went back together. But once i got it figured out it went in pretty good and it rolls up and down like new. I did the same on the other side too. Getting the two windows and trim installed took half a day.

Lastly – the rear tail light panel stuff.

OLYMPUS DIGITAL CAMERAThe tail light buckets turned out to be a real pain. I had to make some adjustments (re; bending metal) to get them to fit. Then I had to replace some of the bolts that had rusted off. I keep having to go to the hardware store to get stainless steel nuts, bolts, and screws to replace the rusted ones.

Once I got the buckets in I put the bulbs in and the new gaskets, old lenses, and new bezels. I had to grind down the heads of the screws so they would fit down in the bezel like the factory ones. After that was finished I wired everything up. Then I put the Gas filler neck on and mounted the gas cap. After that I spent some time modifying the new bumper mounts so they would fit correctly onto the bumper. Then I mounted the bumper. Oh yes, I almost forgot. At some point I also mounted the rear valence. Anyway, that’s all for now. Enjoy the pictures.

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EXHAUSTED

header1I was feeling the need for a little creativity so I decided to work on the rear valance exhaust cut-outs. I wanted something clean and a little custom. I  saw a design I liked on the Dodge Ram trucks where they have a cut-out and subtle body accent line above it and I decided to do something similar.

OLYMPUS DIGITAL CAMERAThe first step was to figure out where the exhaust will exit and then mark the valance accordingly. Of course I had to figure out the size and shape of the cut-out which was a bit tricky since the valance mounts at an angle. Once the height of the cut-out was determined I could then work on the proper shape. It needs to be pretty much of a semi-circle when viewed from the angle at which it is mounted to the car. Once that was figured out I made a template and marked the valence on both ends.

OLYMPUS DIGITAL CAMERAThen I had to cut it out with my 30 year old jigsaw. Above you can see how the tip will fit the opening when everything is put back on the car. Next I had to mold the accent line.

OLYMPUS DIGITAL CAMERATo do this I had to make a template and trace it on the valance (after sanding off the primer of course). Then I spread some DuraGlass according to my lines. After gaining the proper thickness I pressed the template onto the DuraGlass and smoothed around the top edge with my finger to get a nice clean shape. When the DuraGlass started to become a little firm I removed the template.

OLYMPUS DIGITAL CAMERAFrom that point it was just a matter of sanding and adding filler to get the right shape.

OLYMPUS DIGITAL CAMERAThis is what it looks like presently. However, I still have more work to do on the accent lines as I’m not yet satisfied with the look. The edge is a bit sharp yet and the flat area between the top edge and the cut-out is bugging me. Keep in mind that when the valance is on the car that bottom is at a low angle so the accent line will not look that high above the cut-out. I think when I get it all sorted out it will look nice.

The next order of business was to get the fuel tank painted so I can bolt it back in and put some fuel in it.

OLYMPUS DIGITAL CAMERAAbove is a photo of the new tank after being sanded and prepped for epoxy primer.

OLYMPUS DIGITAL CAMERAAnd here it is in primer.

OLYMPUS DIGITAL CAMERAAnd it’s painted gloss black with a single stage urethane.

After finishing with the fuel tank I spent way too many hours crawling around under the car getting it primed, sanded, and cleaned for a final paint. It was nasty, dirty, yucky work but it had to be done. Then, a day or so later, after I was in a better frame of mind, I got out the paint and spray gun and crawled around under the car and painted the underside. It looks pretty good. You’ll just have to take my word for it though because the pictures I took look like blackness with a few blown-out highlights. It’s very difficult to photograph the glossy, black underside of a car.

I was going to mount the fuel tank but all the original screws were too far gone to use. I’ll have to pick up some nice stainless steel screws and get it mounted this weekend.

 

 

 

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I DON’T KNOW, MAN. I JUST WORK HERE

OLYMPUS DIGITAL CAMERAThe garage is a busy place these days. The hood has had way too many hours put into it and I’m sure one day it will look nice – at least for a little while.

OLYMPUS DIGITAL CAMERAI spent some time fabricating and bonding patches for all the holes I cut in the front of the hood. Child’s play. Routine. Didn’t even draw blood or set anything on fire.

Then I spent some time fabricating and welding pieces for the underside of the hood.

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Then I spent more time fabricating and welding the underside of the hood.

OLYMPUS DIGITAL CAMERAIt’s not pretty but it’s solid. It will have to do for a temporary hood.

OLYMPUS DIGITAL CAMERAThen I spent some time on the topside with the filler.

OLYMPUS DIGITAL CAMERAIt finally warmed up enough to spray some epoxy primer. Now that it’s shiny I can see what a terrible mess it is. It’s going to require a lot of work to get it straight.

OLYMPUS DIGITAL CAMERAOLYMPUS DIGITAL CAMERAAbove you can see the other pieces that I was finally able to get into primer. They all look good from a distance but of course there are nicks and blemishes that have to be dealt with.

OLYMPUS DIGITAL CAMERAI straightened up the grill and got it painted. It looks like new now.

OLYMPUS DIGITAL CAMERAI spent a little time prepping and painting the front structure too. It looks OK. Most of it won’t be visible when the car is assembled.

OLYMPUS DIGITAL CAMERAOLYMPUS DIGITAL CAMERAFor the last two nights I’ve been working on the mounting for the drip rail trim. Of course I cut the drip rails off so now the stainless steel trim just fits right up against the body. It’s going to look nice and clean.

I also spent a lot of time working on general body work and I got all the trim holes on the rockers welded up. I decided not to put the rocker trim back on so I had to fill all the little holes. I want this mustang to be as clean and sleek as a coupe can be.

PROBLEMS IN THE HOOD

OLYMPUS DIGITAL CAMERAI know, I know. You’re saying, “Look at all those WORDS! I just want to look at pictures. Where’s the pictures?” No worries. There’s lots of pretty pictures, but you need to read the words first to get the story of the pictures. So read the words first.

I’m a simple guy. I like a simple plan. I had one that went something like this: Work real hard and get the hood in primer this weekend. Sounds like a nice simple plan, right? Of course, but it never goes like that. It just doesn’t.

It goes more like this: Work like crazy getting the hood stripped of paint on the top. Then work like crazy to get the paint stripped from the underside. Get out the cutting tools and cut away the substructure so you can repair the rusted areas. Start sandblasting the rusted areas and watch as the holes begin to appear. Stop sandblasting because it’s warping the metal and then slather Naval Jelly all over the rusted areas. Mess with the Naval Jelly for a couple of hours and then cut the larger rusted through areas out with the cutting disc. Grind, cut, wire brush, scrape and sand rust. Patch some holes, spray some primer and paint, and tack weld the substructure back on. Catch your pant leg on fire while welding. Come to the realization that jeans with fringy holes in the knee are not suitable for welding, and this hood is just toast. It’s too far gone for a proper restoration. It’s got rust in places that I can never get to and no matter how many hours I put into it, one day little rust bubbles are going to start appearing on the top side of the hood.

You might say, “Why not just buy a new hood?” And I would say, “Yes, that would be lovely, but my budget is busted right now.”

So it’s time for a new plan: Do the best I can with this hood and put it back together and get it ready for paint, knowing that I will replace it a few years down the road. I have an idea of a custom job I want to do on the hood and this hood just isn’t worth it. Eventually I’ll find a decent hood, take my time and do the custom work to it, paint it and put it on. I haven’t seen any scoops or anything that I really like on the 65 coupe so I think my custom design will suit me just fine one day.

Now the part you’re waiting for or have already skipped on to; the pictures of all the work for this temporary hood.

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OLYMPUS DIGITAL CAMERAOn a happier note, I managed to get the nose pieces stripped without too much drama.

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OLYMPUS DIGITAL CAMERAAt least these pieces are in decent shape and with some sanding they should be ready for primer. It has finally warmed up down here so maybe I can get some primer sprayed in the upcoming week. Right now the goal is to have everything in primer by the end of the month so I can spend April and May doing the final body work and have it ready to paint by June. I still have a few subtle custom things I need to do on the body so I’m hoping 2 months will be enough time. We’ll see.

 

 

 

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BITS AND PIECES

OLYMPUS DIGITAL CAMERAThings are starting to come together now and I think I see a glimmer of light at the end of the tunnel. Lately I’ve been spending my time in the garage working hard and fast. There are so many parts that need restoring so I’ve been trying to get some of those knocked out as well as the sheet metal body repair. The freakishly cold temperatures down here have slowed me down some but the work still continues.

A while back I took the mud flaps off from under the left fender and they were nasty and rusty of course. I tossed them in the Apple Cider Vinegar tub and let them soak for a week.

OLYMPUS DIGITAL CAMERAAbove is the photo taken after I cleaned them up. They cleaned up great but what I need is the rubber extensions. The old ones were dry rotted so I need to figure out how to make some new ones. If anyone has any ideas let me know. I need a durable, flexible material that I can cut and rivet to the metal flaps.

OLYMPUS DIGITAL CAMERAI had to re-fit the mud flap because it was just a ridiculous fit from the factory with huge gaps. After some adjusting I was able to get a good snug fit.

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The flaps look real nice after the primer and paint.

The next little project was the heater box. It’s so old and warped and rusted I had my doubts about it being savable, but on my limited budget I needed to try.

OLYMPUS DIGITAL CAMERAOLYMPUS DIGITAL CAMERAAs you can see the back half looked ready for the scrap pile.

OLYMPUS DIGITAL CAMERAThe front side of the heater box wasn’t much better than the back. It was somewhat warped and the opening for the little door vent had a piece knocked out of it. In the photo above you can see where I have placed tape on the backside to get it ready for repair.

OLYMPUS DIGITAL CAMERAAnd here it is with the first application of filler. I like to use Duraglass for areas that need a lot of strength. This stuff is really tough. You have to sculpt it quickly while it’s soft, otherwise you’ll be tempted to use profanities and throw tools around the garage in your futile attempt to shape it.

OLYMPUS DIGITAL CAMERAAfter a couple additional coats and some sculpting and sanding it’s ready for primer and paint. (My brother made that little knife in the background and I’ve been using it to sculpt body filler for the past 25 years or so. Thanks Bill.)

OLYMPUS DIGITAL CAMERAWith new paint it looks not quite like new but better than before.

OLYMPUS DIGITAL CAMERAThese are the internal pieces I soaked for a couple of days. Again, not quite like new but better than before.

OLYMPUS DIGITAL CAMERAOh yeah. This is the before picture.

OLYMPUS DIGITAL CAMERAHere are the pieces painted and mounted and ready for further assembly.

OLYMPUS DIGITAL CAMERAThis is the box with the fan mounted.

OLYMPUS DIGITAL CAMERAHere it is from the front. Now all it needs is…

OLYMPUS DIGITAL CAMERAthe front. I just need to get a new heater core and make some rubber seals and do the final assembly.

I also restored a couple of other odds and ends.

OLYMPUS DIGITAL CAMERAThe hand brake turned out pretty nice.

OLYMPUS DIGITAL CAMERAAnd this… this… I forget what this is, but it turned out nice too right? Oh yeah. It’s the fresh air vent control. Pretty high tech stuff.

The other ongoing project was the fender.

OLYMPUS DIGITAL CAMERAHere it is in the first stage of stripping.

OLYMPUS DIGITAL CAMERAAnd here it is almost stripped.

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Above are the pictures of the fender stripped and sand blasted and cut for patches.

OLYMPUS DIGITAL CAMERAHeres one of the patches clamped up.

OLYMPUS DIGITAL CAMERAAnd this is what it looks like on the other side with the patches bonded in.

OLYMPUS DIGITAL CAMERAThis is the top front patch with the first layer of filler.

OLYMPUS DIGITAL CAMERAThis is the lower section with the initial filler work finished.

OLYMPUS DIGITAL CAMERAThese are a couple of new tools I just purchased to help get this job done in a more timely manner. They work great. I should have purchased these tools many cars ago.

The next step was just to get everything sanded and ready for epoxy primer and with my new DA sander it was a breeze.

OLYMPUS DIGITAL CAMERAFinally, it’s in primer and looking whole again.

OLYMPUS DIGITAL CAMERASurprise! I did the front valance too. I told you I was working hard and fast. I’m sure I did some other things too that I didn’t have time to document but that’s OK. This is enough for one post. Besides, I’m tired and I need a little break now.

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THE ART OF THE ABSTRACT

OilAbstractThis project has become a seemingly endless process of cutting, shaping, and welding together oddly shaped abstract pieces of metal to form a larger work of art – a 65 mustang. Right now however it still resembles a bunch of oddly shaped pieces of metal. Hopefully six months from now it will look more like a mustang.

This has been a busy week with much multi-tasking, so let’s get to it.

The major project for the week was to repair the fresh air vent under the cowl. It was very similar to the same repair on the other side only less horrible by mere degrees.

OLYMPUS DIGITAL CAMERAOf course the first steps were cutting away the side to gain entry to the rusted out areas and then to dispose of said rusted areas. In the photo above the rusty stuff has already been removed and a couple of interior patches have been applied. This little project required plenty of pattern making and metal cutting and so forth.

OLYMPUS DIGITAL CAMERAAbove you can see the base sheet metal that I cut for the fresh air intake. Kind of looks like a Picasso hobby horse doesn’t it? Later I added a circular collar (which prevents water from flowing into the floor on rainy days) and I welded in three studs for the mounting of the vent tube. It only took about a hundred test fits and adjustments to get it to fit properly. Then it was bonded and welded into place, sealed and painted and sealed again with truck bed coating.

OLYMPUS DIGITAL CAMERAThis is what the piece looked like as it was clamped into place. It’s always a challenge when working in confined spaces.

OLYMPUS DIGITAL CAMERAAnd here it is after all the bonding, welding and sealing. It’s not the prettiest thing but it should last another 20 years or so and keep my feet dry when it rains.

OLYMPUS DIGITAL CAMERAThen of course it was just a matter of buttoning things back up.

OLYMPUS DIGITAL CAMERAThis is the final repair after paint. I did a little clean up in the wheel well area and on the suspension and painted that too. The frame will get cleaned up and painted later and hopefully sometime in the not too distant future I will be able to replace all the suspension components with cool new go-fast parts. But for now this area is finished.

Another little side project was to repair the fresh air intake vent.

OLYMPUS DIGITAL CAMERAAs you can see in the photo the mounting flange has seen better days. Rather than spend more money I on a new vent I opted to repair this one.

OLYMPUS DIGITAL CAMERASo I made a template and cut out a new flange. I changed the location of the mounting studs for easier access so the flange had to be drilled accordingly.

OLYMPUS DIGITAL CAMERAThen I just spot welded it in place and sealed the seam.

OLYMPUS DIGITAL CAMERAAnd with a little paint it looks almost new.

The remaining project was to get the right fender painted on the underside and the brace welded back into place.

OLYMPUS DIGITAL CAMERAThe inside of the fender is no pretty sight. It has patches and areas with the original undercoating (which I couldn’t get off so it stayed) and a tiny bit of sand from the sandblasting which conveniently blew off the saw horse and onto the wet paint. (That’s why I don’t like sand blasting. It always comes back to haunt me.) But again, not too many folks are going to be crawling around under the fender, although there’s always the odd one at the car shows.

OLYMPUS DIGITAL CAMERAThis is the inside corner that was patched and needs the brace re-attached.

OLYMPUS DIGITAL CAMERAAnd here it is with the brace welded on and painted. Yes, it’s ugly and pitted but it will last and be sturdy and do it’s job and I didn’t have to spend more money on a new one.

So that’s about it for this weekend. Unfortunately it was mostly ugly work and run-on sentences this week. Maybe next week  I can do something nice like the outside of the left fender and perhaps refine my writing skills a bit. Until then just enjoy the pretty abstract paintings and ignore the bad grammar.

Abstract2

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