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  #321  
Old 01-17-2018, 10:46 AM
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juicedz4 juicedz4 is offline
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Location: Rochester, NY
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Good progress last night. Finished shaving the badge holes. Which went pretty smooth and turned out good. They probably wont even need any filler.





Then it was time to tackle the lock hole. I needed to remove the step, but wanted it round and centered if possible. Puzzled it for a bit until I remembered I had this hole saw arbor that lets you expand existing holes. Luckily I had the perfect size saw for the existing hole (just had to go around it like 20x with a deburring tool for a slip fit).





Then carefully cut a circle of steel to fill the hole.



Skipping a bunch of steps, but basically i did a bunch of tacks a few times around to get it fully welded. Then ground, sanded, hammered, sanded, hammered, until we get to here. Its def not perfect and will certainly need some filler, but Im pretty pleased.









Up next is the third brake light. Im either going to shave it completely or shave it but add a thin flush mount LED. I cant find a good pic of what Id like to do, but basically youd just see the lens which would be a piece of lexan sanded flush to the contour of the lid.

Dan
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  #322  
Old 01-17-2018, 12:12 PM
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entropy entropy is offline
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Logging away the stacked hole saw trick!


E
__________________
When did empirical knowledge get replaced by a theoretical education?

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  #323  
Old 01-17-2018, 12:14 PM
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juicedz4 juicedz4 is offline
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Quote:
Originally Posted by entropy View Post
Logging away the stacked hole saw trick!


E
This is what I have:

https://www.mcmaster.com/#hole-saw-e...uides/=1b61ggh
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  #324  
Old 01-17-2018, 12:53 PM
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Graham08 Graham08 is offline
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Quote:
Originally Posted by juicedz4 View Post
Thanks for the tip! I just added one to my next McMaster order.

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  #325  
Old 01-19-2018, 07:35 PM
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CarterKraft CarterKraft is offline
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Originally Posted by juicedz4 View Post
Genius! I always machine a wood plug on the lathe to stick in the old hole then use a 1/4" transfer punch to center the hole saw.

That arbor looks allot simpler and waaayyyy faster.
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  #326  
Old Today, 12:24 PM
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juicedz4 juicedz4 is offline
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Decided to go ahead and shave the third brake light. Still unsure what Im going to do to replace it but for now its gone. Im considering two to replace it; one inside at the top of the rear window for when the top is up, and one on the roll bar for when its down. (obv would have a way to disable either depending on the top position). It would be cleaner and more visible, which is good given the size of this car and the distraction level of drivers these days.

Anyway, I didnt get any pics of it welded up but here we have the filler done and the first coat of primer blocked down. I have a couple low spots and some pin holes to deal with. In general though I think its damn close. A quick coat of glaze here and there and another coat of primer and it should be set. I was surprised that there seemed to be some filler under the OE paint. Perhaps Karman did something with them?









Between filler drying I started working on a fender. Everything is so filthy still.





Shaving the marker lights in progress. The screw holes are already weld up here.



Unrelated to body work, the clutch hydro line and banjo fitting showed. Fit nicely.





Welded the -12 bungs to the HX and got two of the hoses done. Still waiting on some support spring for the lower, suction, hose.







Dan
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