A-man930 Posted December 9, 2019 Author Posted December 9, 2019 Might not look like much, but there was quite a bit of effort put into getting all the packed dirt out from in here. The "frame rail" looks like its in great shape!
Drahcir495 Posted December 12, 2019 Posted December 12, 2019 Any updates on the tdi swap? What did you end up doing for the front bumper? Interesting build
A-man930 Posted December 13, 2019 Author Posted December 13, 2019 9 hours ago, Drahcir495 said: Any updates on the tdi swap? What did you end up doing for the front bumper? Interesting build My TDi is still homeless, sitting on an engine stand in the corner. I keep some ATF squirted in the cylinders and turn it over every once and a while. I'm going to go one more "round" with ye olde 4.0. I've got enough on my plate with this current rust repair/bodywork; it's already been a year since I let the tags expire, I'll be lucky if it's back on the road within the next (year). Front bumper is on the list alongside the rust repair and body. I'll be sure to post progress. Thanks for the comment!
A-man930 Posted January 5, 2020 Author Posted January 5, 2020 I couldn't stand the thought of missing some pocket of rust. Plus, the dust from all the stripping/grinding was everywhere. I'm glad I did: -Note the rust along the windshield seal. -And the upper left hand corner... not sure how bad this is yet
A-man930 Posted January 7, 2020 Author Posted January 7, 2020 Bought some XJ pans from Raybuck. They'll need some modifications but they look like quality pieces.
A-man930 Posted January 18, 2020 Author Posted January 18, 2020 Well it doesn't look as bad as I had feared. Any thoughts on where the water is coming from?
A-man930 Posted January 18, 2020 Author Posted January 18, 2020 On another note, anyone know what this bolt is for?? (circled in yellow) There's another one on the other side.
Pete M Posted January 18, 2020 Posted January 18, 2020 based on the rust at the bottom of the windshield, it would appear that it is your source. But keep in mind that there needn't be only one leak.
A-man930 Posted January 19, 2020 Author Posted January 19, 2020 I'm on the verge of getting somewhat discouraged; I keep finding more rust! I decided to make a few access holes for inspection/clean-out on the driver's side. The first picture is from inside the cab just below the corner of the windshield (you can also see I trimmed back where the rust had bubbled through the seam sealer) The second picture is from the outside, just below where the cowling meets the A-pillar. ( yes, I broke through into the cowl a bit ) Its not pretty in here. I can't trace where the water would travel from the windshield. Instead, I think the cause is a combination of running around with no inner fender liners and condensation. The most frustrating part is where the toe board (firewall?) sandwiches against the "support plate" for the brake booster and steering column... water has been creeping into here for a long time and has made it's mark. There are so many curves and contours... I don't know how I'm going to fix/replace this.
A-man930 Posted January 21, 2020 Author Posted January 21, 2020 On 1/19/2020 at 9:00 PM, Pete M said: can you cover the surfaces with POR-15? Not with a brush. I'll probably end up using some kind of aerosol with a diffuser wand and semi-regularly get a dose of fluid film up in there. I'll also probably try the pool noodle in the fender trick to keep water from blatantly spraying up in that area.
A-man930 Posted January 21, 2020 Author Posted January 21, 2020 Now things are getting pretty well beyond my comfort zone, but I'm still gonna press on! The trans tunnel side moved pretty significantly when I completed the cut on that side; here's hoping my bracing is sufficient and wasn't too late. I tried to limit the number of complex curves and corners that I would have to re-create and here's what I ended up with.
A-man930 Posted February 12, 2020 Author Posted February 12, 2020 On 12/2/2019 at 8:31 AM, Pete M said: it's not impossible to fab your own patches. Got this little gem from my Matco guy: And it works wonders! That's all I was able to knock out today, but man I'm feeling better about it already!
Pete M Posted February 12, 2020 Posted February 12, 2020 it's amazing that a picture can make my ears hurt. fantastic work!
A-man930 Posted February 12, 2020 Author Posted February 12, 2020 2 minutes ago, Pete M said: it's amazing that a picture can make my ears hurt. fantastic work! Thanks!! It is ridiculously loud; I took out the earplugs for a brief moment and WOW. Its almost like I'm jackhammering on a giant metal can!
JMO413 Posted February 14, 2020 Posted February 14, 2020 On 2/11/2020 at 11:00 PM, A-man930 said: Got this little gem from my Matco guy: And it works wonders! That's all I was able to knock out today, but man I'm feeling better about it already! That is a very very nice patch. Good work.
A-man930 Posted February 14, 2020 Author Posted February 14, 2020 50 minutes ago, JMO413 said: That is a very very nice patch. Good work. Well thanks! It's definitely my first rodeo.
Pete M Posted February 14, 2020 Posted February 14, 2020 just make sure you paint both sides of all patches.
A-man930 Posted February 18, 2020 Author Posted February 18, 2020 Got a bit of work done on the Raybuck XJ pans. Welding 18ga is a trip.
A-man930 Posted March 2, 2020 Author Posted March 2, 2020 Got the last puzzle piece fitted for the big patch piece.
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