Sunday, April 5, 2009

Broken Camry, more E9 welding

The first order of business today was to discover the source of a thumpy sound coming the the rear suspension of our 1986 Toyota Camry station wagon. Turned out to be a broken anti-roll bar (a.k.a. sway bar).

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Last week I decided to fill a gap between the lower tail light patch and the existing sheet metal with a little doubler. It worked great, but it interfered with the fit of the upper half of the patch. Work on the E9 today began with cutting a notch in the upper patch to clear the doubler.

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Next came fitting the inboard end. I had two height changes to deal with, one going one way and one the other way. It took a few cuts and a little hammering, but it all worked out.

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The last thing to do before welding was to cut away the top edge in order to create the 3 3/16 in. opening for the tail light. I left some material at what will be the lower left corner of the opening to create a nicely radiused corner.

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For some reason the welding did not go as well as it did last time. I was not getting good penetration. Next time I think I'll try warming up on some scrap first.

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