Two patches RH rear panel

I did not write last week because I was in the middle of upgrading my Fujitsu T1010 notebook. Now it is mostly working, except for a few little things. Like tonight I discovered I cannot import photos from my Nikon Coolpix 5400, the camera I use to take the pictures posted here. So I will make a quick note, and when I have the photos I will expand.

Last week was all about making the larger of the two patches for the RH rear. These are low, under the bumper line, which is why I had to remove the fuel tank.

I began by inspecting more closely the repairs exposed by the removal of all that bondo. This first sequence tries to convey how uneven the surface is.

This patched needed a lot of shaping. To fit perfectly would require tricky compound curves. For this I don't need perfect, just a foundation upon to apply filler. I did spend some time trying to get it to fit nicely, but I wanted it welded in by the end of the day, so when it was as close as I could get it, in it went.

Today began with the discovery that none of the welds higher up were strong, so I had to redo that part. Not a big deal.

Next came cutting and shaping the smaller patch. This one also needed so compound curves but not as radical. I managed to get a closer fit. After welding and grinding I filled in the gaps with POR-15 Epoxy Putty. I also put a fiberglass patch on the small rust-through above the larger patch, using POR Patch.

While the putty set up I went back to the LH side and sanded down the last batch of filler. That high spot under the tail light really causes a problem. I decided to let it show a little, but I did add back some of the filler I had ground off earlier. A compromise. If it takes too much filler I'll try hammering it down with a shrinking hammer.

With the putty mostly set up I continued to play with the TECHNIFILL filler on the RH side. Having discovered why it is so thick over there I know it will require several applications before that area is smoothed out.

Removed tank, found old damage

It took a great deal of will power to tear myself away from the Vikings - Cowboys game. Luckily my Tivo was there. Who could have predicted the final score after the Vikings' opening drive? Brett Favre is still amazing.



I decided to tackle the gas tank removeal first thing, while I was fresh. Turned out to be an easy job ... the tank drops in from above and a PO hadn't bothered to bolt it down!



Before disconnecting the three wires to the fuel gage sending unit I made a note of their colors and position. Standing at the back of the car, looking straight down, the fuel line goes off at 3 o'clock. Just to the right is the brown wire. At 12 o'clock is the brown with yellow dots,and at 6 o'clock is brown with a black stripe. We drained out the two gallons still in it to use in the shop's tow truck. I want to treat the inside with POR-15 Fuel Tank Sealer, but I doubt anyone in Honolulu stocks it.







With the tank out I spent a few minutes inspecting the area and found more evidence of what I already suspected, old collision damage. What surprised me this time was the poor quality of some of the work. My plan is to leave alone as much as I can, and re-do what obviously needs to be done. I need to get under the car and remove that fuel line before I can weld the crack.



I finally got around to removing the white plastic wheel well covers. I also checked out the rubber drain plaugs along the floor ahead of the wheel well and tank area. They turned out to be dried and crumbly, not savable.



The reason for removing the tank, beyond the fact that it needed to be, was to weld this area.



Just a few minutes of grinding revealed a thick coat of bondo covering an old collision damaged area.



I spent a good halk hour grinding away all the bondo. There is no reason for it to be so thick below the bumper.



Look how thick it is, 1/8 in.in places.



I cut out the damaged areas, and cut two patches from my sheet metal stock. I finished with wire brush scrubbing with POR-15 Marine Clean followed by a coat of Metal Prep. Next week I'll shape and flange the patches, and hopefully weld them in.