Well, no real need for a pictorial update. I did as planned. Stripped the entire trunk drip rail and primed it in etching primer. I found a propane torch to be my best tool for that endeavor. Heated the paint till it bubbled, and brushed it briskly w/ a regular stainless steel wire brush. Bare metal in one minute or less 8" at a time.
I went to HD, and bought that flex seal junk, not actually the exact stuff, but a krylon version of the same. It's like sprayable undercoating, only thinner. I sprayed all of the inside seams of the main duct box.
I sealed the area above the rear end tunnel where water will dump into when it rains/ I wash the car with a polyurethane caulk. And I covered the old hole I cut on top of the tunnel with a piece of .030 aluminum plate.
When you look at that part of the car, you'll see the channels formed into the floor to add strength. By riveting a thin piece of sheet metal over that, the low parts of the channel will act as gutters. Water will dump into the enclosure, and run back out through those "gutters".
** not the "after shot", just an old pic so that you can see the area I'm talking about.
I painted the whole trunk floor, and inside quarter area w/ a gallon of Duplicolor Bedliner that I had on a shelf, un-opened since 2007. I read the instructions that told me to shake the hell out of the can for two minutes before application ( which I did). I originally bought this stuff for an old street rod project, and decided against using it for the next 2 projects because of the potential mess. When I opened the can and looked inside, I wasn't surprised to see jello instead of paint, so I stirred it like mad for another minute, and then rolled that junk all over the inside of my trunk.
I was right.
It was messy.
The stupid crap dried to a tacky state in a matter of minutes. If you moved around, and did a spot here and there, then came back to a previously applied section, the roller would try to peel it back off. Whether or not that was due to the fact that the stuff had significantly dried out already, ( which I'm sure it was) the bottom line was that trying to roll paint in, and around the dips and rises of the channeling, into the spare tire well, and everywhere else before you had to revisit an area that was already painted proved to be a pain in the ass. I did manage to get it all covered and left it overnight to dry.
The next day, I painted the shroud in sprayable Bedliner and then reassembled the thing.
The whole painting process on the trunk floor was kinda pointless actually, because it will be finished similarly to how the red car was done, w/ paneled, and upholstered covers along the front, back, and sides, with carpet finishing the floor. I found a hard plastic tool box that I'll make a custom enclosure to recess it into the spare wheel tub, and make a remove able cover for that. That tool box will hold the requisite emergency tools, some basic first aid junk, and a can of fix a flat.
Lastly, I had to solve the cosmetic issue on the trunk deck that will replace the rectangular grille that is there presently.
My buddy
@95BlueStallion recommended that I replace that grill w/ a standard residential louverd return air grille, and weld the piece into the deck and blend it all in.
At first, I rejected the idea, but I started thinking more seriously about it. I bought one and trial fitted the thing.
It would've worked.
The reason that it won't work is two fold:
1. Is that it's paper thin. Probably 24 ga. It bends just by looking at it wrong. The louver vents are so easy to tweek it's too much of a risk to make something this flimsy a permanent part of the trunk deck.
2. Even if I decided to ignore the above, the thing is powder coated. Trying to get that white paint off the thing is next to impossible. I did manage to use the torch and use the same method that I did on the drip rail to remove the paint, but that super thin stuff warps by the time it's hot enough for the paint to lift. Imagine how bad it'll warp if I tried to weld it.
So, I'm thinking no on that, but it did solve the problem.
There are guys out there that punch louvers onto a blank piece of 18 ga. Sheet metal. I think I'll have one if them punch me a plate of 3 rows of 3" louvers that I'll weld in instead.
Just a generic pic from one of those guys. I'll call on monday, and order the panel that'll fit my opening.