Boxes ... and a finished lower cowl

The other day I received a delivery from the states of all the parts that I will need to complete the cowl area including the lower cowl, wiper transmission, wiper motor mounting , motor and export brace.

 

 

Installed the lower cowl using the export black to help line it up due to the previous work done on the car (I use the term "work" pretty loosely) and the repairing of the firewall flange I was not 100% on weather I had left the right holes turns out I had and after opening them up a little and trimming the top edges I was looking good for welding.

 



 

Prepping the lower cowl for install removed the e-coat from the area to be welded and sprayed with 2 coats of copper weld-thru primer the punched and drilled the 8mm (5/16") holes rady for plug welding.

 

Installed lower cowl lined up with reference points and clamped in prep for welding.

 

 

And 1 hour 45 minutes later and 75 plug welds, one completed lower cowl.

 

 

Plug welds all cleaned up ready for priming with weld thru primer.



 

 

 Weld thru primer done ready for the rebuild of the upper cowl.

 

 

Next will be installing wiper trans to help line up the upper cowl and rebuild the pieces removed in the cowl removal process thanks to the mess of a job done previously.



Sub frame connectors

I decided to have a go at making a set of sub frame connectors using Car Daze's plans (see Car Daze Sub-Frame Connectors) and I must say I am very happy how they turned out.  Because I live in New Zealand the cost to purchase a set from the states and get them shipped here with the exchange rate was quite expensive I think they worked out to be about a third of the price and I still have enough steel to make another 2 sets.  Also making them myself allowed me to make some modifications to the rear mount to add more strength for when I add the through rocker exhausts.

Started by cutting the 2" steel to length and marking out the notches for the angles and cutting them.

I made a angle gauge out of a scrap piece of particle board to make sure all the angles are correct and welded the bends.

After welding the bends I ground the welds smooth and created a template for the torque box plates I made these different to car daze because I am going to cut a 3" hole through the torque box for the through rocker exhaust so this allows me to add some strength back I also cut the 45 degree angle at the rear end and welded in a plate to cover the opening.  I have also completed some of the installation phase by cutting the ends off the front frame rails to allow test fitting before fully welding the connectors.

Completed connectors with a coat of paint ready for installation.

Completed the installation of the sub frame connectors which was quite awkward due to not having any jack stands and doing it all from within the transmission tunnel at normal ground clearance.  Very impressed with the result and how much it has stiffened the body it is very noticeable when rocking the body from side to side.

Progress ... all be it slow

After purchasing the rolling body on the 28/03/2013 and finally getting it transported down from Auckland after a few hiccups with transport companies, I finally received the car on the 16/04/2013.

 

After looking at her in the garage every day and still waiting for her new home to be built I decided to start the job that I have been dreading since I first looked at this project... the cowl.  Due to the poor welding that was done in the USA when the donor upper and lower cowl was installed this became a mammoth task and after 5 hours and lots of dremel cut-off wheels the upper cowl was off. 

 

The plan was to repair the lower cowl as the condition was not too bad but after further investigation the welding was that poor it had not fused with the firewall flange and with a air chisel 70% of the welds just let go with no effort, due to this the decision was made to remove the lower cowl, repair the firewall flange and install a new lower cowl.  Removing the lower cowl cost me another 3 hours but this is nothing compared to the work that will be required to repair the firewall flange.  You may also note that the dash is missing in the photo below that is because this also had not been fully welded in and fell out once all the upper cowl spot welds had been removed.

 

After another 4.5 hours all the holes had been welded up 2 patch pieces were welded in the flange and the 2 ends were created (as these were missing), and a whole heap of grinding it was starting to resemble a functional firewall flange (still need to grind the left half of the flange).

 

 Well finally finished the firewall flange grinding and filled in a few more holes.  Also have fixed the plug welds in the a pillars and given it a couple of coats of copper weld through primer to protect it till the replacement part arrives.