Tag Archives: Body Work-Drivers Floor

Applying POR-15 to the drivers side toe-board area

A before shot of the pitted metal in the driver’s side toe area. I didn’t want to patch this, so I decided to use POR-15 on it. (Paint Over Rust – POR is a rock hard coating to prevent further rust.  I used POR-15 Silver along with some mesh from the kit for a small portion by the patched panel to help strengthen the area. Before:
First coat:
First coat dried:
Second coat 4-5 hours later:
Second Coat dried:
Third coat (within 24 hours):
IMG_1631I still need to scuff this once it is dried then prime over it.


Patch Panel Re-weld

Only took me a half day to re-weld the patch panel from the bottom while on the rotisserie.  I must be getting better at welding.

Before pics:

IMG_1581 IMG_1582

Starting with a few tack welds:IMG_1583

After pics:IMG_1584 IMG_1585 IMG_1586 IMG_1587

There were a couple of holes that needed to be closed.  Using this tool from Eastwood to use as a backing while welding them shut:IMG_1588Next, I will be tackling the drivers side toe area with POR-15.


Patch Panel

Wrapped up my cleaning and organizing of the garage, shed, and 2nd floor of garage.  Now focusing on re-welding a few sections of my prior floor patch work.  Before I welded from the inside of the car, and now I plan on going from the outside (bottom) of the floor while it is on the rotisserie.  Today was cleaning and grinding the welded sections both on the inside and inside, then cleaned.  Taking next Thu & Fri off, so hope to be done with my re-welding by the end of next weekend.  The side close to the trans hump area was difficult to get the welding nozzle at, going from the bottom, should provide me with easier access to the areas I want to re-weld.

Inside shot:


Bottom of floor shot:IMG_1569

Feb 9, 2014 Update – Patch Panel

I had some remaining work from the floor patch panel from last summer.  I had to get the old brake bracket off the old floor – will need to weld it to the new floor later.

Here is the bracket on the old floor:


I started by drilling out the spot welds I could find:IMG_0525 IMG_0526

Then I used a body saw to cut it out with the old floor metal still on it:IMG_0527

Then I used my vice to hold it while I worked on getting the old metal off of it:IMG_0528

This body seam buster came in real handy:IMG_0529

You can see some of the spot welds I had missed:IMG_0530 IMG_0531

Used my grinder to smooth the old spot welds down:IMG_0532 IMG_0533Will put this in the blast cabinet and prime it before welding to the new floor.


Sep 28, 2013 Update – Patch Panel

Almost done with the patch panel.  Still need to grind the welds on the bottom and then spray some Epoxy primer on it:

IMG_0387 IMG_0388

After my first pass at welding, looking at it from the bottom showed some areas where the light was shining through that needed to be gone over.  So after grinding the welds, re-welding and re-grinding, I think it is finally acceptable.  Next summer, I will go over the floor and trunk with POR-15 Floor & Trunk kit which should get any remaining pin holes.IMG_0398 IMG_0404 IMG_0405 IMG_0406 IMG_0407 IMG_0408 IMG_0410 IMG_0412 IMG_0413


There are two small areas I think need patched.  Need to verify on NastyZ28.com that these are not factory holes and needs to be patched.  That should then wrap-up the body work until Spring 2014 when I sand and prime the main shell.IMG_0415 IMG_0417

Sep 4, 2013 Update

Latest updates on the patch panel.  Most welding and grinding is done, there are still a few spots to re-do:

IMG_0291 IMG_0292 IMG_0293 IMG_0297 IMG_0305 IMG_0313 IMG_0314

The welder wire got jammed up – had to fix the next day.IMG_0315 IMG_0316 IMG_0328 IMG_0329


Also located a plug I needed (still need to seam seal it in):

IMG_0304Also pictures of a dash I acquired for the interior:

IMG_0348 IMG_0349 IMG_0350Hope to not wait so long before the next update!



Jun 16, 2013 Update

Made some progress this weekend – got the patch panel tacked in place and started welding it in.

Final adjustments for fitting:


All tacked in:IMG_0284

Started welding:IMG_0285

Bought a new work light from Menards – 500 Watt Halogen.IMG_0286Also removed the remaining wiring from the car.  Still need to put a few removed dash parts away.  I finally had to turn on the garage A/C as welding in a welding shirt, gloves, and hat tends to heat the body up a bit!!!


Jun 13, 2013 Update

Received my magnetic plug weld tools from Eastwood – I have a 4×2 plate that I was using, but wanted something a little more versatile:


http://www.eastwood.com/magnetic-plug-welding-tool-horizontal.html and http://www.eastwood.com/magnetic-hole-plug-welding-tool-not-for-gas-welde.html

Also ordered a re-conditioned used AC dash off of eBay.  Didn’t want a re-popped one after reading about fitment issues, so I figured I had better grab a used one while I can!  I’ll take pictures when it arrives.