Today was a working day , but relaxed and easy .
Ramping up slightly for the modifications stage , as when that happens it will be a little less relaxed and easy ....
Remember I busted off the pressed-in captive nut for the battery clamp due to a rusted thread ?
I had a plan , and we get this weekend off so I borrowed a tiny tig set from work (has to fit in the passenger seat of my daily boxster) and I also borrowed one of our appprentices Tyler as he has a gas bottle and truck and happens to love working on cars in his spare time ..
I have him a couple of m8 nuts and he took the zinc plating off while I went to Home Depot looking for the longest 8mm bolt I could find .
The nut was put on the end of the bolt and coerced through the hole before I flattened the metal that had “exploded” outwards as I fought to get the spinning captive nut out then started to tightening down the bolt so it hit the trunk floor so the nut raised to the metal before finishing the are to a standard Tyler was happy to weld .
The welding was done , weld flattened slightly with a flapper-disc, then the area was masked ready for primer .
I was wary of whatever caused the rust on the nut/bolt causing unseen damage within the cavity between the battery-tray and trunk floor so had previously masked and poured in rust remover .
Now it was time to do the same again with bare-metal primer , but instead of making a “bath-tub” of the area and pouring it in like I had done with rust remover and flush , I was going to use a cavity wand .
Once it was masked I simply inserted the wand wherever it would fit and hoped for capillary action.
If I didn’t see black primer coming from the seams between the spotwelds everywhere , I simply added more .
Then masked/stuffed with rags the obvious leaking areas , and added more .
Then added more .
Then ran the can dry and brushed around the seams with a 1/4” brush .
Then used rags to mop up the mess .
Needless to say , I’m confident there is no more rust and no bare metal anywhere in that area !!!
In the next few days I’ll be applying Shultz and finishing off the trunk .
