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Old 03-05-2014, 09:36 PM   #14
MyblackS13
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Join Date: Oct 2002
Location: Indiana
Age: 42
Posts: 128
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After finding the rust in the rails I took a long break from the project. Needed to decide if the project was still worth it and was contemplating a new shell. Long story short, I decided to stay the course. It was a lot of work.

First I dropped out the subframe and tension rod brackets.





I've been learning to TIG weld through this build so the welds are far from perfect aesthetically, but I expect them to hold well.



The passenger side was the worst by far, apparently rust stated underneath the undercoating on the firewall along with the frame rail and where moisture gets trapped at the brake line holder



I welded in spots to give the patch panel some extra bite along with welding around the perimeter







Passenger side after completion. I used silicon bronze rod on the firewall sections for more flexibility and to control heat input a little more to try to have fewer flare ups inside the car.



On the drivers side I tried to make the repair more flush with less overlap





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