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flyboy161 Mon Jan 01, 2018 6:12 pm

I did a little digging around the windshield though

You might remember this from a couple of weeks ago

Ugh! I hate rust

TheDon Mon Jan 01, 2018 6:18 pm

I canít wait to see how you fix this rust.

You should see my car!

flyboy161 Tue Jan 02, 2018 11:11 am

Broke out the Dotco today and went to work stripping the paint and bondo off the windshield channel

Drivers side. Thought Iíd hit the passenger side while I was here

Oh yeah. This is gonna be fun. Did I mention I hate Bondo too?

flyboy161 Fri Jan 05, 2018 10:05 am

Still removing Bondo from the windshield area

Driver's side looks ugly but it's contained

Passenger side actually turned out to be worse but it's contained as well

This is the center section. Some pitting rust filled in with Bondo, but doesn't appear to go through...we'll see

flyboy161 Sun Jan 07, 2018 6:46 pm

Well, I decided to take a look at the back window frame and....

Itís pretty ugly too

Mr. Mike Sun Jan 07, 2018 8:18 pm

Yikes, I fear mine may be in the same shape... I can't wait to see your repairs.

flyboy161 Sun Jan 07, 2018 8:54 pm

I'll be honest Mike, I'm half dreading, half looking forward to the repairs.

EMPIImp69 Mon Jan 08, 2018 6:58 am

You need to cut all that rot out, make up and shape the new pieces, and weld them in.

flyboy161 Mon Jan 08, 2018 8:31 am

Yes sir, I'm just waiting on a stretcher/shrinker so I can start bending some metal. It'll be here Wednesday. I had to work this past weekend and I'll be working next weekend as well, so I'm just in the evaluation stage right now.

I typically work one area at a time to keep from getting to many pots on the fire. So far I've closed up a big gash in the rear firewall. After that I repaired a 6" crack on the hood. Currently the front clip is nearing completion with welding new metal in after cutting out the rot and straightening the bent metal. I will work the windshield area next followed by the rear window. I really despise Bondo but a little glazing putty is unavoidable. And truthfully the only reason I've used any glazing putty at this point was to test the invisibility of the repairs. I'll finish up by revisiting the heater channel repairs I did 3 years ago. Everything else is solid and intact.

Finally, I'll have the car dustless blasted. This is why I'm trying to avoid any putty at this point. It will be removed when the car gets blasted. Hopefully nothing gross pops out of that. Then I'll do my final glazing/fill, prime it and prep for paint.

I don't like looking at the whole project this way, but rather approach it from a milestone point of view. There is no end point in time, I'm just in metal repair mode now. But, I do welcome advice and appreciate all of it.

flyboy161 Thu Jan 11, 2018 3:58 pm

New toys arrived! Got a metal stretcher/shrinker set and some clamp clecos. This morning I got out in the garage and played around with a piece of scrap metal.

This is just an experimental patch, just to get a feel for fabricating a curved piece.

Super easy! Took about an hour to make this one. I wonít install this one, itís too narrow and I need to get better at cutting. But I am pleased with the simplicity of the shrinker/stretcher.

Now to acquire some 20 gauge metal, practice my butt welding, and start making some patches

flyboy161 Sun Jan 14, 2018 5:23 pm

Today I thought Iíd tackle the back window as it seems the hardest to do. There are about 8 holes across the bottom of the window frame. I did one One this afternoon.

I started by bending a patch. Then carefully cut out an area slightly smaller than the patch

Then using clecos I trimmed the checked the patch fit. I started by using a dotco to get it close and ended by hand filing the patch until everything matched perfectly.

Then the welding began.

A lot of grinding

And itís done.

TheDon Mon Jan 15, 2018 12:34 pm

Thatís awesome work. How did you get the curve into your patch piece for the. Rear window channel?

flyboy161 Mon Jan 15, 2018 7:19 pm

Metal shrinker/stretcher Don...

Bought off Amazon
And an 18Ē sheet metal brake

Available at your finer Harbor Freight Stores

TheDon Mon Jan 15, 2018 7:40 pm

I had figured that. But I meant the slight curve the joins the rest of the body work, not the window channel.

TheDon Mon Jan 15, 2018 7:40 pm

I had figured that. But I meant the slight curve the joins the rest of the body work, not the window channel.

flyboy161 Mon Jan 15, 2018 8:06 pm

Ah, that. Ancient Chinese secret. :wink:

Really though, it was just some very light hammer work once it was clecoed in place.

flyboy161 Tue Jan 16, 2018 11:24 am

Here's a step by step of the patch fabrication

Today we'll be fabricating a patch for this area

First I cut a rough piece out of the front clip I bought a couple of weeks ago. This is from the gas tank struts. It's already been through the stretcher to get the radius of the back window. Clamped in place with vice grips I'll lightly hammer the shape to match the curve downward on the body.

Here it is.

I removed it and cut it to size. It is now clecoed in place to check fit.

It required a little more hammer to lay like it should.

After hammering I drew an outline of the piece.

And voilŗ. It is ready to be cleaned up. This was all done prior to cutting the body. I'm using the body as a dolly in essence. Tomorrow I'll clean up the piece to remove the paint and straighten the edges smooth. Then I'll mark the body and cut out the bad metal slightly smaller than the patch.

TheDon Tue Jan 16, 2018 1:02 pm

awesome. thats what I was needing!

thank you for taking the time and photos

flyboy161 Tue Jan 16, 2018 3:24 pm

Glad to help. Once I cut out the pinch seam part of the old metal, the new piece should fit perfectly.

flyboy161 Sat Jan 20, 2018 9:12 pm

While waiting to see if I'm going to be furloughed, I figured I'll keep my hands busy to take my mind off of it all.

Three holes fixed. Now there is glazing putty on it setting up.

Next hole is surrounded by some deep pits, so I'll be cutting out more than I really wanted to

Patch is fabricated

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