[Casey914]

looking good!

[little b]

that is some GREAT Re-fixit body work you are doing!!!!
very clean....

[racer]

Those pesky rubber bumpers can hide a bit, can't they. The great work continues!

[rothaus]

Yes, those ugly rubber things hide things.

I was pocking around in the rear trunk and found 2 areas which looked suspicious.



There were some small rust areas which were masterful repaired with body filler.



After removing the material it showed 2 sections which need some attention.



I removed the exhaust heat shield below.



And found that one of the support was hanging on body filler. That goop of chip guard must have been there since it came out of the factory.



A view from the bottom side.



Here I have the sections cut out.



I made new pieces to be welded back in.



Here they are welded back in. Pardon the ugly welds, I will clean them up.



Here is it cleaned up.



Another view from the bottom side, with the heat shield support welded back on.



Cheers
Engelbert

[Dr K]

Unbelievable. For the 8th photo above (old rusted sheet metal and new part yet to be welded in) - could you please post a step-by-step how you form the sheet metal like that. It's really impressive, and I'd love to know how you do it!

[rothaus]

It's not that difficult. I just bend and hammer it until it looks like the piece I have cut out, except the rust hole.

It's basically like to chisel a lion out of the block of marble.

Cheers
Engelbert

[Vicegrip]

This. Just bend and hammer until it looks right.

A shop press and scrap wood works wonders for making dimples, creases and raised ribs in small bits like above and a vice with smooth jaws for the sharp bends and lips. To make a flat top open ended rib like above for example you cut a strip that is rib wide, long and a bit taller, place it on the press table and then place a thick strip on ether side. (or vice versa) Press it down a bit and check the work as you go. One last press down without the center rib to even things flat. This can produce soft curves, angles or sharp 90s depending on how you set things up. You can step up a bit and get a metal bender that fits into a shop press. Bend thin sheet up to 1/4 thick bar. A cloth bag of sand or shot and some nylon hammers can be used for real odd shapes. I make dimples with washers and sockets then punch the hole after with a chassis or electricians punch. For long thin beads and a lot of other stuff in thin sheet this kind of tool is handy. (example not a recomendation) http://www.northerntool.com/shop/too...Fc1KDQodpJEK5Q

[Dr K]

Thanks for the detailed explanation. You guys are amazing. Would still like to see a video, series of photos, or better yet, IN PERSON!

[DonNewton]

It's become apparent to me that if Kurt and Englebert were to work on a project together that critical mass would result and northern VA would become a smokin' hole.

[dbroxson]

Originally Posted by DonNewton

It's become apparent to me that if Kurt and Englebert were to work on a project together that critical mass would result and northern VA would become a smokin' hole.

LOL, there would be no time to actually document what happened, as the two of them would complete the tasks faster than the plan could be documented...What an insane wealth of knowledge...