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-   -   Waterlogged Rust Bucket (http://forums.pelicanparts.com/showthread.php?t=519605)

blee 09-09-2011 07:54 PM

The suspension pan came out without too much drama:

http://forums.pelicanparts.com/uploa...1315626612.jpg

http://forums.pelicanparts.com/uploa...1315626654.jpg

http://forums.pelicanparts.com/uploa...1315626717.jpg

http://forums.pelicanparts.com/uploa...1315626803.jpg

blee 09-09-2011 08:06 PM

Lots of patching and fabricating...

http://forums.pelicanparts.com/uploa...1315627076.jpg

http://forums.pelicanparts.com/uploa...1315627151.jpg

http://forums.pelicanparts.com/uploa...1315627225.jpg

http://forums.pelicanparts.com/uploa...1315627275.jpg

http://forums.pelicanparts.com/uploa...1315627350.jpg

http://forums.pelicanparts.com/uploa...1315627470.jpg

blee 09-09-2011 08:34 PM

There were signs the car had incurred some front-end damage in it's past. Thought really hard about replacing the whole front clip, but ultimately decided to save as much as I could. The nose seal strip, on the other hand, had too many holes and wrinkles so it came out.

http://forums.pelicanparts.com/uploa...1315628707.jpg

http://forums.pelicanparts.com/uploa...1315628626.jpg
http://forums.pelicanparts.com/uploa...1315628759.jpg

That's when I discovered how much of the damage was "not" repaired...

http://forums.pelicanparts.com/uploa...1315628942.jpg

http://forums.pelicanparts.com/uploa...1315628989.jpg

The nose was pushed in more than 1 1/2 inches in the middle - there was no way the hood was going to latch in that position.

blee 09-09-2011 08:51 PM

This called for drastic measures... the mighty hydraulic fluid, arrghh! arrghh! arrghh!

http://forums.pelicanparts.com/uploa...1315629711.jpg

http://forums.pelicanparts.com/uploa...1315629750.jpg

... and beating on it with a 20 lb. mallet: much better.

http://forums.pelicanparts.com/uploa...1315629778.jpg

blee 09-09-2011 09:06 PM

Tank support in, passenger-side battery box removed, multiple coats of etching primer, rust encapsulator, "Rust Bullet", seam sealer, and Wurth undercoating. She's not going to rust anytime soon.

http://forums.pelicanparts.com/uploa...1315630913.jpg

http://forums.pelicanparts.com/uploa...1315630965.jpg

http://forums.pelicanparts.com/uploa...1315631003.jpg

http://forums.pelicanparts.com/uploa...1315631032.jpg

kenikh 09-09-2011 10:03 PM

He lives - was just talking about your project the other day, hoping you hadn't given up. Great progress. Have you seen Bryan's (combatic) identical pan repalcement last week? Two Br(i/y)ans, same neighborhood, same project, same week...what are the chances?

ant7 09-10-2011 04:56 AM

hi Brian,
realy great work, [Hard work] looking forward to seeing the progress as it happens, should be a neat car when your done!:)
Anthony.

scottb 09-10-2011 07:03 AM

Subscribing. Nice work!!

Rich Lambert 09-10-2011 12:47 PM

Great work Brian!

Are you coming down to Kirkland tomorrow?

CT Mike 09-10-2011 01:22 PM

Great going. Keep it up!

blee 09-11-2011 08:02 PM

Thanks for all the encouragements. I wanted to install a new bracket I fabbed to replace the fender mount that got deleted with the battery box... In order to locate it correctly, I need the fender and bumper back on, but of course, it's never that easy. Both headlight buckets were "repaired(?)" with fiberglass, requiring more drilling, pounding, & welding.

http://forums.pelicanparts.com/uploa...1315799240.jpg

http://forums.pelicanparts.com/uploa...1315799208.jpg

http://forums.pelicanparts.com/uploa...1315799503.jpg

http://forums.pelicanparts.com/uploa...1315799404.jpg

http://forums.pelicanparts.com/uploa...1315799589.jpg
It'll require some additional massaging, but it sure beats creating from scratch. Had I known the rust was beyond the buckets, I would not have been so brutal in removing the donor buckets. Created more work than necessary. :(

blee 03-14-2013 08:28 PM

Still here...
It's been a looooong 16-months since my last post, but I did manage to make a little progress. Reached a few milestones actually. I'll try to bring you up to date: first the fenders. The passenger-side headlight bucket just required a little more massaging, but the driver-side was a basket case. I decided to just cut-off the lower turn signal area and graft it onto a '74 fender. Thanks to Johnny Walker for the fender.

http://forums.pelicanparts.com/uploa...1363321468.jpghttp://forums.pelicanparts.com/uploa...1363321610.jpg
http://forums.pelicanparts.com/uploa...1363321626.jpg
http://forums.pelicanparts.com/uploa...1363321649.jpg

blee 03-15-2013 05:31 AM

http://forums.pelicanparts.com/uploa...1363353726.jpg

As you can see, the big milestone came when the shell was stripped, cleaned, and epoxy coated.

http://forums.pelicanparts.com/uploa...1363353871.jpg
http://forums.pelicanparts.com/uploa...1363353890.jpg
http://forums.pelicanparts.com/uploa...1363353914.jpg
http://forums.pelicanparts.com/uploa...1363353930.jpg
http://forums.pelicanparts.com/uploa...1363353969.jpg
http://forums.pelicanparts.com/uploa...1363353986.jpg
http://forums.pelicanparts.com/uploa...1363354000.jpg
http://forums.pelicanparts.com/uploa...1363354017.jpg
http://forums.pelicanparts.com/uploa...1363354060.jpg

blee 03-15-2013 05:42 AM

Passenger-side rocker:
http://forums.pelicanparts.com/uploa...1363354468.jpg
http://forums.pelicanparts.com/uploa...1363354506.jpg

Uh-oh. Didn't anticipate messing with the door hinge post.

http://forums.pelicanparts.com/uploa...1363354546.jpg
http://forums.pelicanparts.com/uploa...1363354561.jpg

Dug deeper.

http://forums.pelicanparts.com/uploa...1363354600.jpg
http://forums.pelicanparts.com/uploa...1363354617.jpg

Be mindful of this shelf hidden behind the hinge post panel - good thing I was taking my time cutting.
http://forums.pelicanparts.com/uploa...1363354651.jpg
http://forums.pelicanparts.com/uploa...1363354743.jpg
http://forums.pelicanparts.com/uploa...1363354760.jpg

Rich Lambert 03-15-2013 05:50 AM

Brian, I was wondering if you'd given up. It looks like you're getting pretty good at rust repairs.

Actually, I was just thinking about you yesterday. Someone offered me a free 1958 Mercedes 300D that's been sitting outside for years and the first thing that came to mind was rust.

blee 03-15-2013 06:57 AM

Still here Rich. I have decided to consider this a "hobby" and not stress myself out by rushing through the process. Plus I really do enjoy the build process. Glad to hear that my name is synonymous with "rust." Thanks bro!
The old Benz are beautiful cars - too funny, just saw a slammed four-door 240 the other day too. Thought for a "second" how cool it would be to build one, then I slapped myself out of it. Don't you still have the Rover to finish?

Rich Lambert 03-15-2013 07:14 AM

Yeah, the LR is first in line. But hey, I'm retiring next week so I'll have lots of time.

blee 03-15-2013 07:21 AM

No friggin way!!! Wow, I had no idea. Congratulations dude! Then hell yah, go snag it. You know what that means:
http://forums.pelicanparts.com/uploa...1363360850.jpg

Rich Lambert 03-15-2013 07:39 AM

It means you're going to buy me some $700 scotch?

SWEET! You can come over and drink some.

blee 03-15-2013 08:02 AM

No, it means your wife is getting that for you and I'll come over to help you drink it.
http://forums.pelicanparts.com/suppo...s/beerchug.gif[img]

Rich Lambert 03-15-2013 08:09 AM

I don't have any 30yo, but I do have this in the gargage...stop by anytime!

http://forums.pelicanparts.com/uploa...1363363589.jpg

blee 03-15-2013 09:05 PM

Located a donor piece - locally, no less. Thanks for the hook-up Nielsen.

http://forums.pelicanparts.com/uploa...1363409119.jpg

http://forums.pelicanparts.com/uploa...1363409802.jpg

The donor piece required some rust repair too, but the toughest part was aligning the piece so that the hinges end up in the right position to meet the door - lots of measuring & fitting.
http://forums.pelicanparts.com/uploa...1363409824.jpg

blee 03-16-2013 11:16 AM

http://forums.pelicanparts.com/uploa...1363460937.jpg
http://forums.pelicanparts.com/uploa...1363460983.jpg
http://forums.pelicanparts.com/uploa...1363461002.jpg
http://forums.pelicanparts.com/uploa...1363461044.jpghttp://forums.pelicanparts.com/uploa...1363461113.jpg
http://forums.pelicanparts.com/uploa...1363461133.jpg
http://forums.pelicanparts.com/uploa...1363461151.jpg
http://forums.pelicanparts.com/uploa...1363461168.jpg
http://forums.pelicanparts.com/uploa...1363461206.jpghttp://forums.pelicanparts.com/uploa...1363461342.jpg

kenikh 03-17-2013 06:30 PM

Quote:

Originally Posted by Rich Lambert (Post 7330778)
I don't have any 30yo, but I do have this in the gargage...stop by anytime!

http://forums.pelicanparts.com/uploa...1363363589.jpg

Woodinville rye, I see...I'm in.

combatic 03-17-2013 08:27 PM

Brian! You are back at it! Looking good! Hey if you need a hand or anything remember I am just up the street. You can check out my hotrod.

Oh and Let me know when you are going to Rich's to drink whiskey! ;)

blee 03-18-2013 07:02 AM

Rich - I guess we're coming up to drink your Scotch, I meant - celebrate your retirement! Good to hear from you Kenik & Bryan.

merbesfield 03-18-2013 07:37 AM

You mean your retiring from your "day" job. Hope you saved well. Night job w no income can get expensive. Congrats. Cheers.

blee 03-20-2013 08:36 PM

Some inquiries re. the car dolly. I needed something that was "all-terrain" capable to move around in the yard. Three sticks of 4x4x8, couple 2x4x8s, and some scrap plywood to provide lateral support. The castors are from Harbor Freight and have 400 or 500 lbs. capacity ea. - plenty strong. Easy to build and nice height for working on the rockers too.

http://forums.pelicanparts.com/uploa...1363840447.jpg
http://forums.pelicanparts.com/uploa...1363840462.jpg
http://forums.pelicanparts.com/uploa...1363840516.jpg

D@vid 03-21-2013 03:09 AM

Nice dolly Brian. If you don't mind, I'll probably copy that setup when it's my time to restore the 73T. Great writeup by the way.

blee 03-29-2013 06:44 PM

Left hand rocker:

http://forums.pelicanparts.com/uploa...1364610933.jpg
http://forums.pelicanparts.com/uploa...1364610970.jpg
http://forums.pelicanparts.com/uploa...1364610993.jpg
http://forums.pelicanparts.com/uploa...1364611058.jpg
http://forums.pelicanparts.com/uploa...1364611073.jpg

Only a small spot on the lower lock post this time:
http://forums.pelicanparts.com/uploa...1364611346.jpg
http://forums.pelicanparts.com/uploa...1364611360.jpg
http://forums.pelicanparts.com/uploa...1364611400.jpg

blee 03-29-2013 07:04 PM

But the rocker support post required replacing:
http://forums.pelicanparts.com/uploa...1364612499.jpg
http://forums.pelicanparts.com/uploa...1364612513.jpg
http://forums.pelicanparts.com/uploa...1364612525.jpg
http://forums.pelicanparts.com/uploa...1364612538.jpghttp://forums.pelicanparts.com/uploa...1364612616.jpg
http://forums.pelicanparts.com/uploa...1364612629.jpg
http://forums.pelicanparts.com/uploa...1364612643.jpg

blee 03-29-2013 07:15 PM

http://forums.pelicanparts.com/uploa...1364612709.jpg
http://forums.pelicanparts.com/uploa...1364612722.jpg
http://forums.pelicanparts.com/uploa...1364612734.jpg
http://forums.pelicanparts.com/uploa...1364612747.jpg

This part was a little tricky since I chose to fab the rest of this instead of purchasing the whole striker post:
http://forums.pelicanparts.com/uploa...1364612768.jpg

Lots of hammering, fitting, & trimming, but eventually it came out okay. Oh, and don't forget the little step where the sill ends - pain in the ass.
http://forums.pelicanparts.com/uploa...1364612906.jpg
http://forums.pelicanparts.com/uploa...1364612959.jpg

blee 05-05-2013 11:07 AM

Moving over to the lower windshield channels - right side:

http://forums.pelicanparts.com/uploa...1367780643.jpg

http://forums.pelicanparts.com/uploa...1367780659.jpg

http://forums.pelicanparts.com/uploa...1367780675.jpg

http://forums.pelicanparts.com/uploa...1367780788.jpg

http://forums.pelicanparts.com/uploa...1367780808.jpg

http://forums.pelicanparts.com/uploa...1367780822.jpg

http://forums.pelicanparts.com/uploa...1367780837.jpg

http://forums.pelicanparts.com/uploa...1367780851.jpg

blee 05-05-2013 11:15 AM

And the left side:
http://forums.pelicanparts.com/uploa...1367781024.jpg

http://forums.pelicanparts.com/uploa...1367781099.jpg

http://forums.pelicanparts.com/uploa...1367781131.jpg

http://forums.pelicanparts.com/uploa...1367781148.jpg

http://forums.pelicanparts.com/uploa...1367781183.jpg

http://forums.pelicanparts.com/uploa...1367781228.jpg

http://forums.pelicanparts.com/uploa...1367781251.jpg

http://forums.pelicanparts.com/uploa...1367781267.jpg

http://forums.pelicanparts.com/uploa...1367781285.jpg

http://forums.pelicanparts.com/uploa...1367781305.jpg

blee 05-05-2013 11:17 AM

Pain in the arse, but done:

http://forums.pelicanparts.com/uploa...1367781370.jpg

http://forums.pelicanparts.com/uploa...1367781426.jpg

http://forums.pelicanparts.com/uploa...1367781439.jpg

http://forums.pelicanparts.com/uploa...1367781453.jpg

mcaterino 05-05-2013 11:45 AM

Great stuff Brian. Love the can-do attitude.

Mike

merbesfield 05-05-2013 03:08 PM

Looking good. Lots of fun there. It is always so fun patching rust ;)

Rich Lambert 05-05-2013 06:56 PM

Man, you're gettin' good at that!

kenikh 05-06-2013 07:25 AM

JEEZUS, Brian...you're going to be in for a career change after this project. Great work.

blee 05-07-2013 05:11 PM

Thanks for the encouragement. I guess if you own a Porsche, you'd better be ready to fix rust - we've all been there one time or another.

Just a few more rusty spots on the floorpan and the rear seat bottoms and all the rust will have been addressed. Un-friggin-believable! A little more stripping and she should be ready for a nice coat of epoxy primer to lock everything in. A definite milestone.http://forums.pelicanparts.com/support/smileys/wat6.gif


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