I am slowly making progress cleaning up the rot in the engine bay. There are a lot of little things, and some bigger things that need tending to, so this may take a while. Slowing things down is my lack of experience with metal work. I am gaining new skills and experience and trying to do my best job, which means things are slow going. But, I’m happy with the end result when I get there.

After cutting out the square the front left apron by the shock tower, I found a local scrap yard where I picked up some small 14 gauge sheets of steel. The lower plate where I am replacing is heavier 14g and bent down about 1/4 inch on the inner and outer edges. For the first one, I just bent both sides of the scrap and tried to get it to line up as good as possible, including cutting the length before attaching it. All in, I think it worked out pretty well.

For my second patch, I thought I would take this opportunity to practice cutting spot welds. I cut the top layer back and cut the welds out, if they were still there even. This approach also allowed me to save more of the lower metal since I could see exactly where the rot stopped. I was able to save the inner edge and only cut as far as needed towards the shock tower.

I also decided to measure to the bend, but cut the excess material off after I welded the piece in place. That way, I didn’t really have to measure, just cut a straight line. Easier, and better results. I’m still more of a grinder than a welder though.

After that one, I did it two more times and now all 4 of the lower plates are replaced. I needed to wait on my weld through primer before I put the top plates on, so it sat like this for a few days.

While I waited for the primer, I started work on the frame rail. If you remember, it was looking pretty suspect so I took some advice and opened it up rather than just welding it better.

I found a mess. Whoever did the previous work (I wont way repair) put some scrap inside the rail to address pin holes and rot. They then covered it up with a bad patch job.

So I cut back to where it was solid and patched a new piece in. I purchased a part designed to be a patch for the front rail and rail side cap. I just had to cut them to length.

My goal here was to get as much good metal as possible, but to avoid the brackets further back on the rail. I needed to have enough room to cut, weld, and grind, but also be clear of the rot. I clamped the radiator support in place before cutting, so it would hold the place of where the rail was originally.

It took a couple rounds of welding, but the end result ground out nice. First pass left a few pin holes I had to go back and fill then grind again.

I cleaned up the inside the best I could. I also made sure I had a couple inches of overlap for the outer cap for strength on my weld.

I trimmed the outer cap to be the same length as the other side and the previous patch as compared to where it sat in relation to the front of the radiator support flange. Happy coincidence, the cut outs line up with the holes on top the same way they did previously, though I don’t know what those holes are for.

The weld through primer came in, so I coated the inside of the rail on both pieces, wherever there was exposed metal. I used the weld through since part of that surface is also the welding surface for the plug welds. This is my first time doing plug welds, and I think it went pretty well. I need a bit more practice doing the circle, but results were pretty good. It helps that I was learning on thicker metal.

Happy with the penetration on the back side.

Not the most beautiful welds, but I am learning. The plugs look pretty good. The line is a little harder with the two angles and I ended up doing more little sections that I would have liked. But it’s far better than what was done previously. Plus, I’m a grinder.

Weird lighting, but it cleaned up pretty well. When I get some primer on it, the truth will be revealed.

In prep for the next stages, I sprayed weld through primer on all the previous welds I ground out and where I would be plug welding again. From there, I started working on the battery apron.

I really want to keep the hidden VIN on the top of the battery apron, but the lower part of the apron is destroyed. What I decided to do is to cut out the majority of it, but leave the top and the back part, which is solid. I would like to keep the original welds on the back edge and not do something like graft the original VIN into a new plate. I want to make it look like the normal battery rot repairs, if anything. I don’t want it to look like anything fishy with the VIN. It’s going to be a bit more work, but the area is reasonably accessible for working on it with the radiator support off.

I cut the replacement panel down too about an inch overlap on the patch area and clamped it in place where I expect to weld it in. The key driver here is where it will have to be welded to the radiator support and frame rail, so those parts have to line up, then the bend that goes up the back should also flow. I am pretty happy with how it fit, after a bit of hammering on the front lip. From there, I painted the back so I have a stencil of where I need to cut.

With that, I ran out of time, so I will leave the final cut and attaching of the battery tray to next time. At that point, I should also be ready to weld the radiator support back on and put the tops of the apron patches on as well. Slow going, but its going.