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If welding is out, I would agree with @Boosted92LX, Use whatever (3M, SEM.....)panel bonding adhesive. coat little patches of fiberglass and stick it underneath. That stuff will stick like a monster. Use a die grinder to scuff up the underside of the wholes and stick it on the bare metal. If nothing else, it'll be a hundred years before that crap falls off.
Mike, it's not that I don't care about the small Japanese child, you just said you were going to stick the child in your WIFE'S storage? So at that point I don't see where your wife's responsibilities should really be anything for you to worry about.
 
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I will probably attempt to creat a dimple at each hole so the the filler applied to the top will have a slight recess to fill around the hole.

I'll probably screw that up too, and be just as bad off as if I had welded it.

I've done that too, it works, the only downside is the backside of the hole is open to moisture(filler is porous) and it will eventually rust and release. Maybe knock the filler down on the backside where it squirts thru and seal it.
 
I've done that too, it works, the only downside is the backside of the hole is open to moisture(filler is porous) and it will eventually rust and release. Maybe knock the filler down on the backside where it squirts thru and seal it.
How does water get through the paint that is on top of the sealer, that is on top of the primer, that is on top of the filler? Or conversely, how does water get into the passenger compartment, and then fill up the car so much that the "back side" of the hole is exposed to that moisture?

Maybe if I drive the car........in the bottom of a lake?
 
How does water get through the paint that is on top of the sealer, that is on top of the primer, that is on top of the filler? Or conversely, how does water get into the passenger compartment, and then fill up the car so much that the "back side" of the hole is exposed to that moisture?

Maybe if I drive the car........in the bottom of a lake?

How? Because of something you and I are both sadly accustomed to because of where we live, my good sir. Humidity. You can't escape it. Not in this part of the country. Bare body filler soaks it up like a sponge. Now if you were taking yer gila lizard back to the desert, it would be dry and happy.... But down here, seal the holes, or your adobe mud falls off the hut.
 
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Ok then it's settled. Plastic window screen, cut into little chinky doos, applied to cleaned, roughed up metal on the underside, using that Z grip filler (which self etches BTW) and is very flexible ( it takes a dedicated effort to break it off the spreader after it dries, because it wants to bend w/ the stinkin' spreader). Then when its dry, it gets coated w/ bed liner under, and the bottom side is done. The top gets another smear of that same stuff, and I'm da-done-dah.
:banana: :banana:
 
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Maybe if you heated it up with a heat gun around the holes to make the metal slightly more forgiving in that area directly around the edge of the hole. Then hold the round end of a ball peen against the hole and smack it with another hammer for a uniform dimple.
 
Did you back the Monster outta the garage under its own power?
One man power. Battery and fuel system has been disconnected for months now.
Welding, raggedy. Attached electrical systems do not like having ground current pass through them on its way to the metal that the positive electrode is melting together.
 
I'm just stopping by to poke around a little bit. Awesome seeing the car sitting on all fours. Have you let that poor kid out of the crate yet??
That kid will stay in that box, in the dark, by himself for the next three months (or more).
I'm sure he'll be fine,...a little quiet time will do him good.
 
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Maybe if you heated it up with a heat gun around the holes to make the metal slightly more forgiving in that area directly around the edge of the hole. Then hold the round end of a ball peen against the hole and smack it with another hammer for a uniform dimple.

In the grand scheme of things, the previous body guys may have already did that for me. I'm not gonna mess that span of metal up smacking any of it w/ a hammer, especially after heating it. Besides, a heat gun will not get the steel malleable enough to bend, it'll just get everything about a foot around it hotter than hell.

No, said the finger.:nono:
 
In the grand scheme of things, the previous body guys may have already did that for me. I'm not gonna mess that span of metal up smacking any of it w/ a hammer, especially after heating it. Besides, a heat gun will not get the steel malleable enough to bend, it'll just get everything about a foot around it hotter than hell.

No, said the finger.:nono:

This is why you are a fabricator and I am a mere bolt on type guy.
 
Remember when I said that the garage was so full that I couldn't move?

Well it's raining.

I can't move any of the junk out to do anything. So I'm jammed up, unable to walk around the front of the car, barely able to walk behind the car. Nonetheless, I try to do something.

I strip the driver side door opening.
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And after putting it out there, I decided to plug the holes that span the roof w/ knead-able epoxy, applied from the underside, and left to dry.

What it left me was a kind of Coolio looking kinda thingy happening on the roof.
01a0927c3041b641ee18b6df3b8e3ffa12feebf2c0_zpss3bbw5fd.jpg

So, I'm thinkin' I'm leaving my boy Coolio's mini-dreads poking through the roof till tomorrow. I'll cut them off flush w/ the roof, slightly undercut the sprig, smear it w/ filler, and call it done.
 
Last week the wife asks what I want for Christmas. I tell her I'll have to think about it, as this will be one of those Christmas's that I need nothing for the car. (And I always get car parts as gifts.......she knows better.)
So bottom line, I need nothing really.
After thinking about it, I tell her that I could use some HF wheel dollies, and just to be safe, my angle grinders are probably about to go. She asks how much that stuff is and I tell her, The wheel dolly set is about 120.00, and the 4-1/2 angle grinder(s) are a little over 20.00 each. I tell her I'll need two, one for cutting, and one for grinding. That way I can leave the respective wheel attached w/o having to change blades/wheels all the time.

That's all?

Yep.

However, no sooner did I tell her that, and grinder #1 takes a dump. Typical HF failure,...the brushes wear out. Although they include another set most of the time, the stupid plastic caps that hold the brushes in are fractured, so when I go to replace them, the cap comes out in pieces.

I hail mary the thing into the trash can.

Now I'm down to 1.

Fast forward to today, and grinder #2 slows down in my hand. I smack it, and it speeds back up. The rest of the day, It struggles to do what I needed to do, eventually giving up the ghost as well. I throw it down to the ground, as hard as I please.

They lived a decent life. They managed to get through more than 3/4 of the way through what will amount to be a 3 year build.

This however creates a dilemma. I now need two new grinders, and there is still 3 weeks till Christmas. I simply can't wait that long, especially considering that I have a fair amount of cutting, and grinding in front of me.

Guess I'm getting socks for Christmas.

What I managed to get done before Thing #2 took a crap was get the other bumper extension pretty much complete. As with everything I do where there are two, the second piece is always easier, or better, of took less time, or required less work. This was the case w/ this side as well.

The driver side extension is made up of 6 separate pieces of steel, the passenger side was half that. The driver side took 8 hours, this side took 4.
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FEA7EB82-58A2-4019-BEB8-AEA8FB50F704_zpsmghulmno.jpg


I still have to cut the piece of steel where the overlap is, and butt weld the extension in place, but it's getting there.

Also, since the fenders are on, I took the opportunity to check for interference when turning.

B93BD158-19DE-4303-A33D-9B24950CA534_zpspgpx3ek7.jpg


The tire hits the fender at full lock. The clearance that is there is laughable because any dip in the road w/ the tires turned will result in a hard scrub. The front end has gotta come up an inch.

Had I not bitten off so much other custom fab crap with this car, I'd consider going back to the drawing board, and bulge the fenders, and quarters Ala Capri, Then throw on some big assed 295's up front, and maybe a 335 or bigger rear.

But,.....ain't gonna happen. I have more than enough on my plate if I ever hope to get done in time for spring '16.
 
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Coolio? Always wondered what your inspirational background music was. Fantastic Voyage blaring out of the Gila hole would make sense. I got to the conversation late, but did the same on some old truck doors after removing the big arsed semi mirrors. I refuse to use cheap stuff in my shortcuts, so mine said "J and B Weld" on the package.....lol.
 
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I love this thread. Every time I complain to myself about how much a PITA it is going to be to do something to my car, I look at this thread and realize I have it easy...and I go out and go to work on the car. Lol. Thanks Mike. :)
 
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Coolio? Always wondered what your inspirational background music was. Fantastic Voyage blaring out of the Gila hole would make sense. I got to the conversation late, but did the same on some old truck doors after removing the big arsed semi mirrors. I refuse to use cheap stuff in my shortcuts, so mine said "J and B Weld" on the package.....lol.

I only associate Coolio w/ Gangsta's Paradise.

That way, the first part of the song becomes almost always appropriate when I start working on something..

" As I walk through the valley of the shadow of death, I take a look at my (grinders) life, and realize that that there none left".......

And for the record,....you have you Gila orifices wrongly identified.

The only noise that should come out of the Gila hole is exhaust noise.
The Gila fin - fan noise
The Gila gills - fan noise
The Gila nostrils - under hood noises.
The Gila vents - are TBD. They used to be on the back of the original hood, now that's gone. That leaves a G vent designator still un assigned.

All of the Coolio noises will come from the little Japanese kid.

While JB weld has been the staple of what I've used everywhere on my glued together car, it is far from the good stuff......you find out what is, when you butcher a super victor intake manifold to the point that it would be impossible to be able to weld back.
This scenario is what I did to myself when I decided to put 16 fuel injectors on said manifold. Had my machinist make me two mounting rails per side, each rail accommodating 4 injectors each. Then had him cut two staggered tiers on the runners so that the rails could sit on. T
What that left me with were areas that couldn't be accessed w/ a TIG, leaving the only option to glue the rails on instead.

After using conventional JB however, you find out that JB will not withstand exposure to methanol, and you have to heat the manifold in an oven to get it hot enough to cause the JB to fail, and start over......W/ some stuff from GE aerospace that costs 125.00 for 8 ounces, that they supposedly used to hold the space shuttle heat tiles on, and go to town.

Being careful to " not get it on you, and especially away from your eyes".
Because for the same reasons it is impervious to methanol, it's also impervious to lacquer thinner.
8 hours later, it dries to what looks like melted glass. Hard as a damn diamond.

And the .030 piece of aluminum that I used as a mixing board?......

As a test, I hit the back side w/ a hammer, I tried to curl, fold, wrinkle, bend, and twist the metal to get the thin layer that was left to fracture off, but it wouldn't. If it's got to tolerate getting to absolute zero on one extreme, and whatever temp the back side of that tile would get to during re entry, it should certainly be able to withstand my little " smack it with a hammer" test.

That is the good stuff.
 
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