Top Banana Challenger

[Challenger6pak]

Your car is going to look great!!!

[Super Blue 72]

Very nice model mock up!  Nice job on the bumble bee stripe! 

[Lunchbox]

Well I was going to work on the cowl today but instead I finished up some other work I had to do on two other projects. Here is a couple of pics of my DS inner fender I removed about a week ago. This weekend I will hopfully have the cowl off the car.

Lunch

[Lunchbox]

I got some more work done this weekend. Removed the other inner fender along with the cowl. The inner fender was easy but the cowl was a pain along the windshield line. Once you drill the spot welds there was not way to get a blade behind it to pop any stubburn welds left clean off. Got it done though.

Heres some pics.

[74chall]

NICE WORK! 

[Lunchbox]

Thanks it was kindof scary at first but then it got better and better. The cowl and the rear seat are going to the blaster this week so I can see the damage that I will need to repair.

The second to last picture shows the sealer that was between all the joints. It looks like it was applied then the two pieces were then welded together.

Does anyone know wha stuff to use to replicate the factory process?

Thanks

Lunch

[farmboy70]

Try using a good weld through primer and coat the hole thing in a product like POR-15 or Rustbullit before welding (not the weld seam).This will give you much more protection than the spongy type sealer that the factory used. It holds water and is why it rusted to start with along with no paint protection.
Looks like you are moving right along , those cowl welds are a pain!
Dave

[Lunchbox]

Try using a good weld through primer and coat the hole thing in a product like POR-15 or Rustbullit before welding (not the weld seam).This will give you much more protection than the spongy type sealer that the factory used. It holds water and is why it rusted to start with along with no paint protection.
Looks like you are moving right along , those cowl welds are a pain!
Dave

Thanks Dave 

All your help has got me here and is keeping me going.

I have the weld throught primer (SEM)

I also have a product called Zero Rust that Resto Rick sells. I belive it is along the line of a POR-15 and/or a Rust Bullet. I have read many bad things about POR-15 and heard first hand from several body shop guys 

One problem I have is the corner of the window. The rust has come down that and got under the firwall as well. Not sure what to do there, lots of compound bends to try and re-create, any sugestions?

Thanks

Lunch

[farmboy70]

Post a picture of the area I'm guessing it is the same area I  replaced on mine (first couple pages in my post) On that one I had a donor piece to use.Let me know how much of the area you need I may have a piece to use.
Dave

[farmboy70]

Probably here?

[Lunchbox]

I know its bad for sure in the red circle between the layers of the a-piller and the firewall. Im sure it will be bad around the yellow circle once I blast it a little this next weekend.

I will get some better pics next weekend when I work on it again.

I will let you know 

[farmboy70]

I checked my parts and I have these if you need them. Shoot me a PM if you want them, one side has a small hole but it is in the flat area so it maybe easier to fix.
Dave

[farmboy70]

  Man my pictures stink lately!!!
Dave

[Lunchbox]

Got some ore work done this weekend. We got the both built for the blasting area. We made a simple 2x4 frame then used plastic and duct tape to seal it all up. I bought a compressed blaster for about $100 bucks and 200 lbs of black sanding media.



There was a slight learning curve with the blaster but once we figured it out it worked pretty good. We borrowed a help from a guy that made a halo out of felxible rubber hose. The halo had a buch of holes in it around the circumfrence. Then when I was blasting hooked it up to a air hose running 15 psi, kept the dust out of the helmet. The take would hold 50 lbs of media and it would take about 15 minutes to blast thorugh it all. Then I would take a break to let the dust settle down a little bit. We are going to make a better door for it and maybe hook up some filters and a fan to help keep the dust down a little.

Heres some pics you can view the before pics above.

Lunch

[Lunchbox]

Here are some pics of the few bad spots we found. Not very many pin holes but will easily be fixed with the MIG. There was some pretty bad pitting around the cowl vent area. The blasting would only get it so good in some areas leaving some of the deep pits (black in the picture). Is this okay to prime over or should I cut it out and put a new piece in?

Lunch