Good idea on taking the door off, I'll see what I can do about that and seeing what's going on in there. The cowl will be interesting, any tips on getting up in there to get a good coating of POR all over that area? This will be a new adventure for me but I expected this so it will a chance to learn something.The door jambs look like they can be saved. In my opinion the best way is to remove the doors. Then you can really see what's going on and it can be repaired. I would imagine you will need a few patch panels welded in at minimum. For the cowl area, use a shop vac and vacuum all of the crud out of there. Then scrub it down with a wire brush and POR 15 all of that surface rust in the cowl.
Yeah that dash is coming out sooner than later. It will be interesting to see what's behind there. I do plan on replacing the heater core while i"m in there. I only want to pull the dash out once.With that seam in the cowl area having rust do you think the dash needs to come out and the firewall insulation removed to check for damage and seam sealer that has given up the ghost? That insulation could have gotten wet at some point t and need to be replaced as well.
I know that is extreme but would hate to let it get worse if it’s there. Sounds like the dash is going to come out anyway so something to look at.
Wholly crap batman, now I feel bad, I didn't realize it was that way.
Don't hate me. Next time you're near me you can poke me in the eye.
Hehe, well my welding skills are non-existent so I may have to look at finding a body shop here in the Orlando area that I can work with. I had planned on cutting my teeth with welding when I replace the radiator support but I haven't bought a welder yet.That door jamb needs attention for sure! Looks about how mine did and it was all cut out and replaced with a donor piece (click link in sig below to see what all got replaced). The easiest way would be to secure a clean donor door jamb and replace it that way, cutting out all the factory spot welds and putting it back in like the factory did, that's how Kevin did mine. That will not be a small job, but if you have patience and somewhat decent welding skills you can do it. The dash will need to come out, the door will need to come off, wiring out of the way, and *maybe* the windshield too depending on what you find as you start taking it apart.
Oh that... yeah that was total screw-up on my part.I just realized that you mentioned a broken oil pan bolt? I had that oil pan off and just stuck a couple bolts in to hold it on,, A little more on this please.
Yeah I've heard about the welding technique. I may have to give it a try once I buy a welding setup for when I do the radiator support. I just need to figure out what kind of set up I need. It was mentioned earlier in the thread that I should be looking for 140amp MIG welder and those are running around $500 - $600 around here (Home Depot / Lowes). Once I get a setup, then I'll need to practice on how to actually do it before I try it on anything that really matters (core support, block, etc..)To remove broken bolts (especially ones flush in the hole) I weld a nut on the end of the broken bolt and slowly work it back and forth to remove it. There are plenty videos online how to do this, but it has worked every time for me.
About a year ago I bought a pair of GT40P heads that had all but two exhaust bolts rusted/broken off - two or three intake bolts too. It took multiple attempts to get some of them (if weld penetration isn't good enough you will twist the nut off - then just clean it up and try again) but they all came out and I didn't need a single extractor tool. Once they were out I simply chased the threads with a tap to clean it out and all is ready for when I want to use them.
A 140 MIG would do well, just make sure you get one that can accept the welding gas so you won't have to use Flux Core wire and that will reduce the splatter and mess and give you cleaner welds.Yeah I've heard about the welding technique. I may have to give it a try once I buy a welding setup for when I do the radiator support. I just need to figure out what kind of set up I need. It was mentioned earlier in the thread that I should be looking for 140amp MIG welder and those are running around $500 - $600 around here (Home Depot / Lowes). Once I get a setup, then I'll need to practice on how to actually do it before I try it on anything that really matters (core support, block, etc..)
I'm in it for the long haul on this car so I'm taking it slow and trying to make sure I do it right the first time (or at least the second time )