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I'm also curious to find out what size holes to drill for the spot welds. Any suggestions?
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Michael O'Neal -
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Old 05-26-2006, 05:36 PM
  Pelican Parts Technical Article Directory    Reply With Quote #21 (permalink)
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Ok, today's update. Well...it's in! My welds (60/70 or so...ugh!) got progressively better as I went along. I first sprayed the underside of the new piece with some zinc/weldthrough primer. Then center punched and drilled a million holes about an inch or so apart. I set the piece in, then did a VERY important step that a fellow Pelicanite (Thanks!) instructed me to do: I PUT THE GAS TANK IN TO FIT THE PIECE. This is so important, I'm going to say it again. PUT THE GAS TANK IN THE CAR BEFORE YOU WELD!!!! Otherwise you're in for some trouble if it's wrong.

Anyway, I marked a couple of key spots, then broke out the welder. It took me a couple of hours straight to get the piece fitted and welded in. It really required a lot of hammering and dolly/screwdriver work to get right. I also used a couple of cheater screws to tighten the piece down when I welded, then welded the holes up when I removed them.

Here's the cavity with the zinc/weld thru primer over the POR 15 on the edges:



The piece on top:



By the way, that was DJ with the great tip on the gas tank. I've also been refurbing my gas tank throughout this whole process.

The beginning of the welding, clamps in place:



I found that I could clamp, and use a hammer with a screwdriver to get the holes flush to the body. I'd skip a few holes, weld one up, then work backwards. I also kept switching sides to give the metal a chance to cool in between. I started dead center, then worked my way out to the edges.



Finally, after a couple of hours of welding, intense fitting/shaping, I finally welded up the last hole. There's a notch cut in the thing on the front driver's side that seems to have no purpose. There's a gap between it and the body, so I might have to silicon that spot or something.

Viola! Done!:



So, I'm off to grind the welds down, hit the whole thing with POR-15, hit it with some 3m Rubberized undercoating, then finally a little paint for the whole trunk area. Whew!!
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Michael O'Neal -
69 RSR Clone(ish) - Read about the build: http://bit.ly/69porschersr

Follow Rennch on Instagram: https://www.instagram.com/rennch_app/
Old 05-27-2006, 01:20 PM
  Pelican Parts Technical Article Directory    Reply With Quote #22 (permalink)
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Ground, buttoned up, and POR-15'ed. Time to start working on the other end of the car again.



I've never done anything quite this extensive before, so it was a good learning experience. I hope others benefit from this thread.

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Michael O'Neal -
69 RSR Clone(ish) - Read about the build: http://bit.ly/69porschersr

Follow Rennch on Instagram: https://www.instagram.com/rennch_app/
Old 05-27-2006, 03:17 PM
  Pelican Parts Technical Article Directory    Reply With Quote #23 (permalink)
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Ok! The final pics. my camera was being flaky, so I didn't get a chance to upload these.

I POR-15'ed everything, taped off my wired, undercoated everything, then painted it all a uniform color. I also refurb'ed my gas tank, ground the edges and POR-15'ed and painted it.

Here are some final pics:



With the gas tank in. I picked up new stainless hardware from the local hardware store to bolt the tank in.:



And a few more pics:

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Michael O'Neal -
69 RSR Clone(ish) - Read about the build: http://bit.ly/69porschersr

Follow Rennch on Instagram: https://www.instagram.com/rennch_app/
Old 06-02-2006, 11:39 AM
  Pelican Parts Technical Article Directory    Reply With Quote #24 (permalink)
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