Still nosing around

Saturday was the usual short day, just three hours. I was able to focus on the E9 and got a lot done, given the time. A great follow-on the Friday's long session.

Started with roughing up the POR-15 applied yesterday, followed by a layer of Technifill. While that set I cut out the patch for the big gap in the RH edge. Once I got started I just kept going -- I do enjoy working steel. Session ended with welding the patch in place.

My new car cover for the Lotus arrived. Put in on over the old one, just until the suspension parts arrive. Didn't get to work on the punch list.

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Patch welded and filled

From time to time an interesting car turns up at the shop. Today it was a very clean 1967 Ford Mustang, driven by a guy about my sons' age. I hope he did not get tired of me yakking about it reminding me of my youth. I was a senior in high school when that car was first sold.

I replaced the battery in the E-9 wall clock, and in my Miller welding helmet. Both were a success. I also changed the bulb in my work light, but it still does not light up. How much can go wrong with a halogen light? Time for a new one already?

With the helmet working I got right to welding. Everything went perfectly except for the grill mounting tab. I had to do it three times before it stuck to the patch, drilling and grinding through the bad weld each time. Must have wasted thirty minutes on that one spot weld. It did end up rock solid.

After grinding I wire brushed everything, especially the exposed weld-thru primer, then just as a precaution applied a generous coat of POR-15 Prep and Ready. When that was dry I filled everything in with POR-15 Epoxy Putty, as usual.

Next week we have a gamelan performance, so I may not make it to the shop.

At last, back to patch making

After weeks of distraction I finally got to work on the E9 today. I did get a late start because I had to help my wife with her bike, and I am still constrained by short hours, but I did get something done. Even a little progress is better than no progress. What I need is more "visual progress," something dramatic. Like painting that car ... imagine that!

In the last E9 session I had started working on the next patch, on the lower edge of the LH grill opening. It was rough cut outline, still flat. Today was all about bending and trimming. Along the way I had to determine how much warp was in the body and work that out with a hammer and dolly. I got to where I was ready to weld, but experience has taught me two things: 1) do not weld at the end of a session when you are tired and rushed, and 2) with fresh eyes I will spot more places where the fit is off and needs a tweak. So, next time will begin with touch-up fitting and shaping, then move into welding.

As an aside, the places where I left steel naked along the top edge have still not started to rust. Naked, but treated with POR-15 prep. I see where they changed the name to Prep and Ready. Whatever they call it, it's great stuff.

Finish welding the nose

Today I finished welding the nose. By nose I mean just the top edge, there is more to be done lower down.

Last week I started working on a little patch to finish the center section. Today started with refining its fit and welding it in place. Tricky because it has so many twists and bends.

After lunch I whipped out the last patch, on the RH side. This one was relatively easy, just a little curve to match the original. Had enough room to slip in from underneath due to the doubler having rusted away there. I wanted a flange along the front but I had to scale it back due to the extra layers of sheet metal already there.

If finish up with some photos of the front as it looks now. To me it looks a lot better, but the condition compares well to that of an accident victim right after surgery. Next week I should be able to start filling these areas, and then it will begin to look like its old self. At the same time I can get started repairing some rust damage lower down, especially along the lower LH grill opening.

Just for fun, compare that last photo of the center grill and roundel section with these:

Roundel mount patch #2

After a bit more head scratching I decided to slide the patch towards the LH side of the car (to the right as viewed). Trimmed the patch and the opening to make it happen.

After lunch I went outside to take a picture of the day (summer is finally here) and happened across these two sorrowful members of our junk yard. A Rolls? Really?

At last it was time to weld. Painted the back side of the patch with 3M Weld-Thru primer but this time I left the mating surfaces clean. Drilled holes to weld through. Wire brushed all weld areas.

Ginned up a way to hold patch in place using a punch, a screw driver and vise grips.

Welding was my best ever. The trick is to focus the heat on the thicker patch material then let it ooze over into the adjoining body panel.

I had enough time to get started on the next patch. This one will close the hole below the RH side of the new patch and stabilize that side.

Patch for nose center top, #3

Continued working on the LH side of the patch to lower it. Drilled holes to weld through. Wire brushed inside surfaces to remove paint. Painted patch and inside surfaces with Weld-Thru primer. Welded on patch. Ground welds. Applied light coat of acid-etch primer.

While was waiting for paint to dry I removed the LH front fender vent ornament. All four holes were cracked. Maybe by design?

Next Sunday is All British Car Day so I will be showing the Lotus at Kapiolani Park. I might drop by the shop in the afternoon.