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Ryoken's Guide to Rust Treatment and Bodywork 101

if you released the sheetmetal welds from the bodyline down, could you push it in?
 
you shouldn't have fully welded that with that bottom bulging out..

I welded the bottom real good because I was afraid it would bust loose if I didn't because of the tension on it

That front lip and bottom are worse than swiss cheese from all the drilling and weld cutting
 
if you released the sheetmetal welds from the bodyline down, could you push it in?

I think I could push it in if I loosened the weld even below that...probably the bottom 1/3 but it's going to be nasty because the welds aren't pretty little dots anymore...they are huge hole filling welds
 
I dunno if it will go much though...I forced it on with a 2x4 Only way I could get it to go
 
i'd do that... a cutoff wheel shaving at the welds, till the surrounding area is thin enough.. bust loose with screwdriver, etc... once loose, trim up those areas with said cut off wheel, weld in correct place...
 
I dunno if it will go much though...I forced it on with a 2x4 Only way I could get it to go


block of wood and a BIG c-clamp that will actually go to the inside of the post... or you could try ratchet strapping it...
 
Do I still leave the welds at the very bottom on the underside lip?
 
no release it all at the lower 1/3... work from the top down, getting it even with the door.. the very bottom will be the last welds.. you will need to reclamp/strap/position it a few times as you work down...
 
no release it all at the lower 1/3... work from the top down, getting it even with the door.. the very bottom will be the last welds.. you will need to reclamp/strap/position it a few times as you work down...

It would be reassuring to know that no matter what I do to it it can be fixed by more welding....and i hope the bottom doesn't spring back when I release it...oh well...learning on the job...:confused:
 
OK...good news is it's done and it is as good as I can get it...

bad news is that the front lip was so mangled that it now looks like a dry river bed.

I am going to have to mud the face of that lip with something that won't crack or let go

Photos coming
 
Look at this...there was barely anything left to weld...looks like you can see through it but that's reflection...it is not yellow gold behind there...the camera flash is causing the reflection off the jamb

2013-02-24_6_zps160a1791.jpg
 
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grind it, than hit it with the sandblaster, than drag some dynaglass in it..
 
I think I am going to have to mud up that front part of the quarter and long board it using the door as a guide...that low spot near the bottom is where I used sheet metal screws to hold it in the first time I installed it...and from using the 2x4 leverage...I got no choice but to build that up
 
There is no lip on that lower part that lines up with the rocker...it is just the thickness of the sheet metal. I see a little bulge coming down in that photo...I think I did that when I used the spoon to try to make that gap a little wider...
I'll tap it back up with a hammer.


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Is it OK...is it horrible?

I haven't worked this hard for such a small little gap in a long time...no jokes please :eek1:
 
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