Re: 1980 Pontiac Sunbird Formula: Project Phoenix
Posted: Sat Feb 18, 2017 10:08 pm
Progress!!
Finished welding in the patches where the previous owner hacked holes for speakers. My welding skills got better as I progressed but I still have a ways to go before I want to attempt something that is more cosmetic.
I also tackled the crusty header panel repair. The side of my original panel was good but the bottom where the battery tray was had a lot of rot. I had planned to just make a flat panel and weld it back together. Then I stumbled on to an NOS one on eBay. Paid more than I should have but what the hey. It was not an exact match so I am guessing it was for a Monza. It was close enough and with some persuasion it fit pretty well.
Here is the original post dissection.
It actually came out easier than I expected. Drilled out about a dozen or so spot welds and it pulled right out.
Test fitting. The shape on the bottom was a little different so I trimmed it a bit. I also had to make some replacement pieces for the bottom of the front part of the header panel. It had a number of small rust holes
I welded it in a bit at a time mainly with welding through the original spot weld locations. I ran a full bead on the two cut edges. I'll grind them a bit but I am planning to put in a new battery tray here so much of it will be hidden.
I need to trim the front edge a bit but I am pretty pleased on the results.
Finished welding in the patches where the previous owner hacked holes for speakers. My welding skills got better as I progressed but I still have a ways to go before I want to attempt something that is more cosmetic.
I also tackled the crusty header panel repair. The side of my original panel was good but the bottom where the battery tray was had a lot of rot. I had planned to just make a flat panel and weld it back together. Then I stumbled on to an NOS one on eBay. Paid more than I should have but what the hey. It was not an exact match so I am guessing it was for a Monza. It was close enough and with some persuasion it fit pretty well.
Here is the original post dissection.
It actually came out easier than I expected. Drilled out about a dozen or so spot welds and it pulled right out.
Test fitting. The shape on the bottom was a little different so I trimmed it a bit. I also had to make some replacement pieces for the bottom of the front part of the header panel. It had a number of small rust holes
I welded it in a bit at a time mainly with welding through the original spot weld locations. I ran a full bead on the two cut edges. I'll grind them a bit but I am planning to put in a new battery tray here so much of it will be hidden.
I need to trim the front edge a bit but I am pretty pleased on the results.