Started off sanding down the POR-15 Epoxy Putty applied last week to fill in the welded patch. Not much to say except it takes time, even with #40 paper. Tough stuff. Eventually I could see I had some low spots, so I decided to use TECHNIFILL, because I didn't need much thickness, and it sets fast.
What I finally concluded is that the hardener has, well, hardened. After a lot of kneading it still came out a thin blue liquid, when it used to look like blue toothpaste. But I could feel a big lump in the tube. And, like the last couple batches, it was slow to harden.
While waiting for the filler to set I used my CP grinder to expose the rust damage along the lower RH grill opening. One spot might need a welded patch. After that I worked on the top of the center grill opening, getting the opening equal on both sides. I discovered the the RH side needed to be built out a little more, so I mixed up what was supposed to be a hot batch of TECHNILL and put some on top of what was still not set. Hopefully next time will not begin with removing a bunch of half-dry filler.
The LH column of the center grill opening is pushed back a little. I tried bending and hammering, but the "U"-shaped cross sections makes this difficult. Rather than risk distorting or breaking this delicate piece I decided to try building it out with Epoxy Putty. After that I treated all the newly exposed areas with Marine Clean and Metal Prep.
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