Weld through spray

I use a weld through spray made of zink as protective layer before I weld the double layer metal together. I dont know how effective this is, but I intend to use some sort of undercarriage spray to penetrate between the metal sheets after painting the car. But I cant understand anything else that this is a rust trap how you do it, if it's supposed to look factory stock. Next time I will weld the NOS support metal for the rear bodymount.

Closing the rear end

The rear end of the heater channel has a distinctive profile. Luckily the outer panel was intact so I had to make the inner part. This was also timeconsuming, and had to be made in three pieces. I was looking to get good solid welds, because this is a very exposed area on the car. It all turned out Ok at last. Final grinding is still necessary to make it lokk satisfying. I also remebered in the last second to add the new mounting nut for the running board before closing the channel.

Closing the corner

It's always a little tricky to make ends meet (not only economical) and make things look right. To remove all evidence of rust and make fresh metal meet in every corner, I hade to make som new small pieces in the intersection between the heaterchannel and the inner wheel well. This proved to be difficult as the piece had double curves. It would have been nice to have a leather bag to punch against, but with some improvisation it fit at the end. It's both good and bad to know there is just a similar corner left =) I know how it's done, but also how much work there is behind it.