Slowest resto ever - Project AmsterFoose / Current subject: The rear window edge

[Don C]

That was pretty bad. How about if you used the screwed up crooked piece, installed it straight and welded in a small piece to match to the rest of the panel. That way you won't have to try duplicating all of the complex bends.

 

[92GTS-R]

Great work, I have never tried wielding, My own car needs work, but I think I will end up taking it to a specialist chassis company.

What are you using for rust treatment on the other parts and on the new bare metal?

 

[Vinnie]

That was pretty bad. How about if you used the screwed up crooked piece, installed it straight and welded in a small piece to match to the rest of the panel. That way you won't have to try duplicating all of the complex bends.

That’s a good idea, however.... I flattened it to figure out how much sheet I needed. Also if I do happen to get a spot welder this will be an excellent piece to test on.

Hey, at least I get to develop fabricating skills

 

[Vinnie]

What are you using for rust treatment on the other parts and on the new bare metal?

At the moment I just put zinc spray where I can because the car will get de-rusted and primed during the dipping process.

 

[Vinnie]

Had a spare few hours and managed to get the indentation at the bottom side in. Actually starting to look like the original now:

 

[Vinnie]

So I bought a shrinker and stretcher but the stretcher works like crap so it was back to ye olde hammer and anvil!

I managed to whip my insert into shape:

The inert is a bit too narrow so I have to add some sheet to it:

I’m pretty impressed with the things you can do with a hammer and anvil. It is very time consuming though but hey, this is afterall the slowest resto ever

 

[Don C]

Well done. ::goodjob:: 

Blacksmiths used to (and still do) make some amazing things with a hammer and anvil. Not a fast process, for sure. I knew half a dozen old gold miners and some ranchers, they repaired, sharpened, or made many of their own tools, and one old-time blacksmith that was a wizard with metals. I enjoyed watching them, wish I had learned more from them.

 

[Vinnie]

This is turning into a very expensive piece of metal with all the hours I put in it! Why could it not have an easier shape? I know folds make sheet metal a lot stronger but really?

Anyway, finished welding some extra sheet to it and started using my favourite tools again; the hammer and anvil!

That corner in the last pic was a joy to create ;-)

But it’s ready to be tag welded in place. How should I make the final weld? Mig around the edges?

 

[protouringstang73]

I would fill up the gap in the corner with a good nice fat weld and then grind it down and make it look good. The rest I would tack weld and then prime it and put down a nice sealer to make it look good

 

[Vinnie]

I would fill up the gap in the corner with a good nice fat weld and then grind it down and make it look good. The rest I would tack weld and then prime it and put down a nice sealer to make it look good

That corner will get filled up indeed. Tag welds and sealer is almost like spot welds and sealer so I guess that would work indeed, thanks!

 

[protouringstang73]

Yeah that’s kind of the same, I actually think I ment spot weld as you say But it should work anyway

 

[Vinnie]

Today I started repairing the damage I did while prying the old taillight panel out:

Looks like there’s enough left to work with

I’ve been test fitting the new taillight panel as well. It should be a good fit which really makes me wonder why the PO did such a crap job putting the old one in all crooked... The old one also sat too high so I’m also wondering how having it lower (= normal) affects closing the lid. Guess I need to get some clay to figure out howmuch space there is...

 

[Vinnie]

Found more crap and decided to create new edges.

Before:

After:

 

[Vinnie]

Alrighty, bit more progress.

Finished the RH bottom corner:

Mocked up the taillight panel:

Cut off half the trunk corner:

Welded in a new half:

It’s coming along. Once this is done I can start on the LH side.

 

[jpaz]

And the more you do, the better you get! Keep up the good work and before you know it you will have that part done and will feel confident to do some more.

 

[mach71351c]

And the more you do, the better you get! Keep up the good work and before you know it you will have that part done and will feel confident to do some more.

+1

 

[Vinnie]

Righty. Finished the RH side trunk corner, what a pita to weld and grind all those corners:

So moving on to the LH side I test fitted the new trunk corner and noticed a few things were off. So I compared it with the RH side original (what was left) and saw this:

That angle about an inch from the top is not in the right spot! It should be lower... Another fine example of rubbish aftermarket crap that’s out there... Gotta think of a way to work with it now...

At least one side is ready now.

 

[Fabrice]

Nice! Way to go @Vinnie!

What matters is the lip for the rubber, the rest isn't that hard to form. I've seen you hammering more complex shapes!

 

[Vinnie]

Tonight I corrected the LH side of the trunk opening. Dunno why but there was an odd bend in it which made the tip of the trunk lid touch.

Before:

After:

I also discovered a new use for my trusty anvil. After cutting the panel, due to stress in the panel the cut warped. By hanging my anvil to the edge it straightened out and I could weld:

One more item off my million things todo list

 

[Carolina_Mountain_Mustangs]

One thought. If your car is not a 73 you will need to weld up the holes for the bumper filler panel along the bottom going across.