Build Thread '83 T-top Coupe - Welding Holes in My Rear

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I finished it! Albeit with a few dirty welds since the argon gave out.:nonono:

The rear of trans tunnel required a little persuading, but it's done. While I was there, there was a small 1.5" crack at the top of the rear floorpan, so I welded it up.
IMG_4677.webp

Then began the front trans tunnel/firewall match up section. The new pan bulged on the left side, I don't know if it's due to a difference in '87^ mustang's trans tunnel or because this pan was pressed in china.:shrug: It was about a 10" section. There was no beating this into shape. At first I took my die grinder with a cut off wheel and made a small slice in the upper and lower areas where the bulge started. That wasn't enough. I took my grinder and widened the gap a bit. That worked. I welded in the center of the cut area and then ground a little more off each end of the cut area so the ends would matchup when pressed together. So, yack, yack, yack, pictures. Notice how dirty, porous and ugly the welds are here. Those last four were a challenge, especially since I had to use one hand to hold the metal down while welding with the other.
IMG_4678.webp
IMG_4679.webp

Then I welded up my slices and dressed them since they were so ugly and dirty looking they were offending me by their mere presence. Look at all that brown around the weld at the top of the tunnel.
image.webp

Here's the next small project, the front seat brace. It really fits pretty nicely considering it's of oriental persuasion!
IMG_4683.webp

Tomorrow I'll smooth the welds in the immediate area the brace goes and a few others. Drill the welding holes in the brace itself. Then I'll clean up the pan and POR15 it prior to the brace. I'll even get the underside as well.

If there's any time left over I'll grind down the 1x1 tubing to get ready for the ladder system.
 
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When the sheetmetal overlaps, drill and install sheetmetal screws to pull the pieces together.

Or if you are really fancy, use the aircraft fabrication method and use clecos

View: https://www.youtube.com/watch?v=lgEIVUVLrnQ


The wingnut variety can really pull metal sheets together
KWN-5-32.webp

Sheetmetal screw would've been a good idea Joe. Especially for the trans tunnel! Some times I don't think through things completely, lol.
 
I finished it! Albeit with a few dirty welds since the argon gave out.:nonono:

The rear of trans tunnel required a little persuading, but it's done. While I was there, there was a small 1.5" crack at the top of the rear floorpan, so I welded it up.
IMG_4677.webp

Then began the front trans tunnel/firewall match up section. The new pan bulged on the left side, I don't know if it's due to a difference in '87^ mustang's trans tunnel or because this pan was pressed in china.:shrug: It was about a 10" section. There was no beating this into shape. At first I took my die grinder with a cut off wheel and made a small slice in the upper and lower areas where the bulge started. That wasn't enough. I took my grinder and widened the gap a bit. That worked. I welded in the center of the cut area and then ground a little more off each end of the cut area so the ends would matchup when pressed together. So, yack, yack, yack, pictures. Notice how dirty, porous and ugly the welds are here. Those last four were a challenge, especially since I had to use one hand to hold the metal down while welding with the other.
IMG_4678.webp
IMG_4679.webp

Then I welded up my slices and dressed them since they were so ugly and dirty looking they were offending me by their mere presence. Look at all that brown around the weld at the top of the tunnel.
image.webp

Here's the next small project, the front seat brace. It really fits pretty nicely considering it's of oriental persuasion!
IMG_4683.webp

Tomorrow I'll smooth the welds in the immediate area the brace goes and a few others. Drill the welding holes in the brace itself. Then I'll clean up the pan and POR15 it prior to the brace. I'll even get the underside as well.

If there's any time left over I'll grind down the 1x1 tubing to get ready for the ladder system.
Good on you Dave!....Still glad it's you an not me.

One things for sure,..you'll have something to really be proud of. Nothing better than knowing that there is no compromised/patched part of a rusted panel as opposed to a complete replacement of the whole thing instead.

The car will be enviable Dave......Right up to the part where you put the sleeping pill under the hood.:runaway:
 
Welcome to Dave's Garage for the Mentally Unstable!:nonono:

So I go out to the garage today to grind down about 10-12 welds where the cross brace goes, right? You with me? 10-12 welds to be dressed......

I had to get about six welds on the rocker panel, they dressed soooo easy. That got me thinking I should go ahead and get the rest along the rocker, makes sense, right? Now it's just about 70-72 welds.

Then I couldn't help but look at those ugly welds I did. I mean, sure, they'll be covered with dynamat and carpeting. What if someone were ever to pull my carpet up and dynamat to check my welds though? Ok, ok, I'll get those. So 90-95 welds now.

While I smooth out the uglies I got to looking at the other welds......they're a little high.......So 170-180 welds dressed.......

But that's where I stood the line though! I'm not some simpleton with a completion fixation problem here! Am I? No, NO! By Gripthor's Hammer I am NOT.

So here's progress so far. I'm getting ready to crawl underneath now to see if anything needs grinding there.
IMG_4685.webp

Then I'll sand some areas and red scotchbrite the other areas, clean it all up and lay out some POR15.
 
So I broke out my little compressor and my 3" DA and some 80 grit sandpaper and went to sanding. Predominantly the rocker panels, but also the rusted areas on the lower firewall where it meets up to the floorpan.

I also used red scotchbrites to scuff the other areas I intended to coat, including the whole floorpan.

I took some wax and grease remover and cleaned everything up after I blew most of the dust out.
IMG_4686.webp

Then I got out the POR15 and a little 4" foam roller and the cheapest paint brush I could buy and went to town.
IMG_4689.webp
IMG_4690.webp
IMG_4691.webp

That's it for the day. I did clean the weld areas on the undercarriage too.

Tomorrow I'll stop by our local welding supply store and get a new can of argon so I can get the cross brace.
 
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So I broke out my little compressor and my 3" DA and some 80 grit sandpaper and went to sanding. Predominantly the rocker panels, but also the rusted areas on the lower firewall where it meets up to the floorpan.

I also used red scotchbrites to scuff the other areas I intended to coat, including the whole floorpan.

I took some wax and grease remover and cleaned everything up after I blew most of the dust out.
IMG_4686.webp

Then I got out the POR15 and a little 4" foam roller and the cheapest paint brush I could buy and went to town.
IMG_4689.webp
IMG_4690.webp
IMG_4691.webp

That's it for the day. I did clean the weld areas on the undercarriage too.

Tomorrow I'll stop by our local welding supply store and get a new can of argon so I can get the cross brace.
Freaking awesome Dave! Love to see what’s next.
 
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