Considering unorthodox repair

[MTyler]

So I thought I'd better get a good look at what's going on with the other side. If you look at the pictures you'll see that the top of the rocker/sill stamping is gone. It was perforated, I just cut it out. /there's also perforation through to the footwell. Would there be anything wrong with patching this from the inside, and removing material from the sill and the kick-panel? Also, any tips about how to remove rust from those inside surfaces

[Nissanman]

Well, well, it looks a lot like the repair I'm doing as we speech, except I'm doing the LHS.
http://www.311s.org/phpBB2/viewtopic.php?t=7759
Take note of what panels go where and just re-build it from the inside out
That rust on the inside of the pillar does look awful but it is only surface rust.
If it is badly pitted and in your opinion lacking in strength, then more surgery is required until you are back to decent thickness metal.
You can try shoving a wire brush up inside to clean it up as best you can.
Providing the metal is sound, I would repair the rust outs and at the appropriate time, squirt a dose of Cavity Wax inside all the boxed in areas.
That is what I intend to do with mine.
You might need to drill a few access holes but they will be hidden ultimately.
It just isn't practical to clean all those inside surfaces back to shiny metal
Even using zinc annealed sheet is not the answer because any decent amount of heat will destroy the zinc surface.
Spot welding is the only way to avoid that problem and one of those is not normally a type of welder one has in the home shop
Make sure you create some drain holes in the base of the "A" pillar.

They are necessary to allow condensation to drain from the box.
You're on the right track, makes the possibility of a 'glass repair a bit out of the question, doesn't it

[MTyler]

You're on the right track, makes the possibility of a 'glass repair a bit out of the question, doesn't it

Ill advised at the least

[MTyler]

Got back on the roadster rust the last few days. Had a piece temporarily pop-riveted in place to establish fender mounting holes, and thought I would use stainless captive nuts in hopes of avoiding the total bolt failure I experienced this time around. I cut shoulders on the nuts on my little lathe so they dropped self-centering into the holes, Then brazed the nuts to the sheet metal. Today I hope to pattern the piece forward of the piece I've been working on.

[MTyler]

Some more progress on the rocker/door-post area:

Here are the pieces to go in:
http://www.flickr.com/photos/13359925@N02/2622049341/ title="Patch Panels by capmconnundrum, on Flickr">


The 'floor' of the doorpost tacked in
http://www.flickr.com/photos/13359925@N02/2634549549/ title="DSC_0001 by capmconnundrum, on Flickr">


Rotted part of door-post replaced:
href="http://www.flickr.com/photos/1335 ... 635372840/ title="DSC_0006 by capmconnundrum, on Flickr">


Rocker nose clamped on, needs a bit more massaging.
http://www.flickr.com/photos/13359925@N02/2635372124/ title="DSC_0007 by capmconnundrum, on Flickr">


Tried the fender on and the brazed on stainless captive nuts line up pretty well. The fender looks like it will go back in the right place

[S Allen]

Mark,

It looks like the links you are using are the problem. I went to your flickr picture of the patch panel and copied the properties and it shows up fine. It looks like this:
http://farm4.static.flickr.com/3233/262 ... 31.jpg?v=0

And when I put it in the image tags like this:


Oh by the way-those patch panels look great. A far cry from the fiberglass you were talking about in the beginning. Nice job.
Steve

[MTyler]

Some more progress on the rocker/door-post area:

Here are the pieces to go in:



The 'floor' of the doorpost tacked in:


Rotted part of door-post replaced:


Rocker nose clamped on, needs a bit more massaging:


Tried the fender on and the brazed on stainless captive nuts line up pretty well. The fender looks like it will go back in the right place

[MTyler]

Rocker nose welded in:


Some red primer:


On to the left side now

[legato]

i am going to have to do the same thing cuz mine is rotten, but i am lucky enough to have my family body shop at my disposal, i am going to be taking a part tha resembles the shape of the end rocker piece and beat it into the shap i need.

[MTyler]

Looks like you're going the whole nine yards. Good work!

[S Allen]

Legato-wow-what a project you have under taken. I thought my 67.5 was bad-- yours is much worse. Keep us posted on the progress. I also added a picture from your album as your avatar.

Mark, I fixed all of the flickr broken links on this thread. Pictures definitely tell the story better than words.

Steve

[Nick64]

THAT LOOKS AWESOME.
I have to do that too at some stage But with less trepidation.