Let me know what zinc you're using. I'm using the U-pol copper coloured weld-through primer but that stuff looks like it covers HARD.

I've still got some of that U-Pol copper - using it to use it up. I'm not using it under the car. Sort of hard to weld through (I tend to scratch the spot a little with the wire before pulling the trigger). The red zinc coating is from Max - it's pro grad stuff, so you have to watch it as it comes out of the nozzle fast. It's self-etching as well. It's not two-part (Max makes a variety of two-part coatings in an aerosol). I'm also having great results with the welder dialed up to the flat setting for 14 ga. Just pull and watch the puddle fuse to the top of the hole then get out. When I get it right (which hasn't been all that often) I'll get a little divot just like a spot weld.

https://www.autobodytoolmart.com/spray-max-1k-self-etch-weld-thru-primer-3680001-p-14527.aspx

https://www.spraymax.com/en-us/products/product/primer-primer-filler/1k-self-etch-weld-thru-primer/

Still working through the backlog of video. Doing what I can guys.

Did someone say "More videos?" Of course they did.

I got my YouTube notification so for a change I just sat down and watched it. I’m so far behind on the other videos I think I’m first... Crazy amount of work to get just that, but it looks absolutely amazing!! Seriously looks like an OEM part!

Thanks Jim - I was pretty happy with how it all turned out. I still have a big backlog of video to wade through...I've gotten a bit behind.

Rocking and rolling back in August...haven't got much done since this video - but there is hope.

Its gotta feel good to get some primer onto that car. There is something about seeing something all one colour that really brings the goal into sight. You’ve made some great progress this year!

Chad.

I thought it was time to switch things up a little and actually completely finish something on this project. So the rear of the car, for years...has been close to finished. Close. But not finished. The sheet metal was roughly fitted and held in with Clecos and the rear seat bulkhead was out, but held in with Tek screws. I have stretched the rear inner fenders 20 mm or so and re-crafted the original back seat back to fit (the base fit fine). But I had never finished up - it needed some filler and the seam sealer was rough, and it was a little scratched up from having to remove the previous Dynamat installation.

So I got to work (see the vids) and got this done. It took almost 3 weeks to complete. Here's the back seat bulkhead welded in.



I had just slopped some epoxy primer on it a few years ago, so that had to get sanded off and this photo is mid prep for the rest. So some parts done, most not done.

You can see where the strip was added...you can't feel where it was added.



I then returned to the trunk to get that sorted out. Lost of paint on the inside of future box sections and many, many plug welds later I was sanding and almost ready for some filler.



Drivers side fender is a little artsy as I will be carrying a spare tire.



Inside and out were then filled with a short strand waterproof filler and finished with some very nice Evercoat Ultra. No pin holes, easy to sand. The perfect filler.





I then broke out the paint guns (I like painting) and treated the metal to two coats of PPG Epoxy Primer (DP48LV) - don't use cheap epoxy - it's nothing like the real deal. Note, I filled the old speaker hole in the parcel shelf area.



I think it came out great.





Getting in all the nooks and crannies was a challenge...thank goodness for fan control.





Ya, that'll do. I still have to change the outer wheel housing - so that's why that's not painted.



I also did the complete rear underside - so that's all done. It needs seam sealer, but that can wait until we're laying colour and done the rest of the sheet metal work back here. For now, the IRS is back up at home and we're moving onto the front of the car again.



That's it for this update.

Crazy amount of detail work as always, nice to see some paint going down.

Just so Jim is up to date!

I've been a bit busy with work...and we added a new member to the team.



He doesn't like the garage a lot just yet, but I have hopes.

So with the back finished enough for now, it's back to the front of the car. Before the frame can go in, the pedal box for the floor mounted pedals needs to go in and the transmission tunnel needs to be replaced. So let's get on with the show.

The engine position meant the pedal box needed to move towards the outside of the car about 1/2" No big deal, I had the room. Just a little more metal massaging.



Final position - seems fine.

Fit is still good.



The pedal mount plate welds directly to the frame - it's 1/8" plate and should be more than enough once fully boxed.

I had to create a relief in the box to cover a gap between the box and the frame - the box ended up going a little higher on the firewall than planned, so this was easiest.



I'll fill in the sides and front so that crap doesn't collect in the gap.



Here's the inside.



I'm also working on the transmission tunnel. It's a bit tight on the drivers side...reverse switch is on the sheet metal.



I think I'll just bend it out a little...this should do the trick.



240 tunnel all cleaned up - looks like a good fit once the front panel was removed.





I should get the sheet metal flange built to receive the trans tunnel this week. Then mount up the rear end and see what I have to do for the drive shaft tunnel.

I like the return to pics with a description, the videos are great for seeing all of the work that goes in to say hand forming individual pieces. But the pics are nice to just stop and get a feel for the bigger picture.

Yes, I can't say that the YouTube thing has worked very well. Sure I reach a different "audience" and I like making the videos, so will continue to do these and post. But I'm never going to devote the time and effort it takes to make it really good...and it's a Volvo so the audience will be small. I don't really care anyway - I was trying to get away from all the effort in making these posts and the photobucket thing.

That said, all of this is just for fun anyway. Just trying to keep the community alive.