Reply to "2548's Restoration"

As you might imagine, after having to repair so much rust damage, I have a keen interest in preventing it from happening again. While I had it torn apart, I spent some time looking at it to see why the rust formed where it did, and what I could do to prevent it. Any place within sight of a tire needs extra attention for rust prevention. The tires throw up sand, rocks, road debris, water, salt, tar, and all manner of trash. This junk hits anything nearby like a corrosive sandblaster. Any coating will eventually be eroded away, exposing the metal, which will also succumb.

Rust also forms anywhere debris and water are trapped. It’s impossible to prevent all water and debris from getting inside the unibody structure, so it is important to give it a way to get out.

My approach is to coat the underbody metal with epoxy primer. In areas exposed to the tire blast, undercoating will be used as well. Splash shields will protect the most vulnerable areas, and be removable for repair or replacement as needed. Some extra drain holes may also be added.

I started making the templates for these shields before I finished the A pillar work, because the area is easier to get to. Here is the cardboard and tape mock up:



The lower round hole is for the antenna wire, which I’ll not be using, so I will plug it. I’ll make a cover for the obround hole in the longeron, and cover the upper round hole along with the gap that is exposed into the ventilation cowl.

Here the area is cleaned up and the obround hole is covered:



The shields are held in with sheet metal screws:



These pieces are ready for their first coat of paint. The center and right ones are for the left front wheel well / A pillar. The left one in this pic is for behind the left B pillar. It would normally be hidden by the gas tank.



The more complex shields are made in pieces. It is easier to make them that way, and also to install and remove them.



Stay tuned for my next installment! Rodney