bjhines Posted July 26, 2006 Share Posted July 26, 2006 These are some pretty good pics of rust repair on a "rust free" 240Z... This stuff was minimal and most of it was not visible yet... There were 2 places that had a surprising amount of damage caused by a leaky rear deck gasket/lid... 1. right hand toolbox... 2 right rear wheelwell/ rocker lip... anyway here are some shots of the damage... somwhat cleaned up to find the extent of the damage... right rear rocker lip... I got a bunch of bondo out of this area... rear hatch lip... both sides actually.. middle was fine windshield lip on drivers side only... never showed drivers side dogleg... I got a big plug of bondo out of here too... I have actually been picking the edges to form a lip.. right and left rockers were pretty clean... right... left... repairs contiued.... Quote Link to comment Share on other sites More sharing options...
bjhines Posted July 26, 2006 Author Share Posted July 26, 2006 First off.. the easy repairs... Windshield area.. I can't find pics of the hole cutting, picking, and patch... patch welded in a ground out roughly.. patch sanded and blasted... Left Dogleg Area: Patch cut and shaped to fit... patch fitted in place.. I picked a lfange for it to fit into flush... patch welded.... ground out roughly... blasted and prepped for bodywork... Rear Deck Lid : This was done on both sides.. This is one section of metal I added to back up the thinned out rusty stuff.. patches welded in and blasted from bottom... completed deck lid patch ground and blasted with a hole for a camera cable... ... Quote Link to comment Share on other sites More sharing options...
bjhines Posted July 26, 2006 Author Share Posted July 26, 2006 This is the tricky stuff here... Right rear rocker lip fix : Hole prepped for repair... outer patch cut and flanged... inner patch cut and formed... outer patch fitment... inner patch fitment... initial welding inner and outer... flushing outer patch with rest of rocker... ground down as well... outer lip capped and ground smooth... ... Quote Link to comment Share on other sites More sharing options...
bjhines Posted July 26, 2006 Author Share Posted July 26, 2006 The repairs were going to get the lead treatment.. but I think I can better prep the repairs and get rust treatment into all the nooks and crannies better with modern chemicals.. I have a few quarts of metal prep and POR15 (light grey)... that should provide a good amount of rust protection... everything will get seamsealer.. with attention given to not trapping water.. I will final fill with bondo where repairs are visible... this will require minimal bondo work as I was very carefull to keep things as flush as possible... I always leave a slight depression around repairs.. but in many cases it is only a few thousandths below grade.. and the areas are relatively small... The large repairs such as the rear rocker lip replacement are DEAD FLUSH.. only slight filling near the weld seams is required... Quote Link to comment Share on other sites More sharing options...
olie05 Posted July 26, 2006 Share Posted July 26, 2006 Cool stuff! How long have you been doing this for? My first attempt at cutting out my floors and welding em in was bad, I couldn't imagine doing any sort of cosmetic repairs. Quote Link to comment Share on other sites More sharing options...
bjhines Posted July 27, 2006 Author Share Posted July 27, 2006 This V8 race car project is the most extensive metalwork I have ever done on one project... most of my experience has been with aluminum and polyester/epoxy... sheet steel is relatively new to me... I like it though... steel MIG welding equipment is MUCH CHEAPER than the TIG equipment I have used in other people's shops. I have not been able to justify the expense of a proper TIG rig with my wife... I have had my hands in kit cars, kit planes, and restorations of everything from gas pumps to turbojets... I was lucky to work for a small shop owned by a retired aircraft fabrication genius.. for several years while I was in college... Quote Link to comment Share on other sites More sharing options...
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